Nordson Encore PE User manual

EncorerAutomatic Porcelain
Enamel Powder Spray Gun
Customer Product Manual
Part 1612502−01
Issued 8/18
NORDSON CORPORATION •AMHERST, OHIO •USA
For parts and technical support, call the Industrial Coating Systems
Customer Support Center at [phone]
This document is subject to change without notice.
Check http://emanuals.nordson.com for the latest version.

Part 1612502−01 E2018 Nordson Corporation
Table of Contents
Safety 1.......................................
Qualified Personnel 1.........................
Intended Use 1..............................
Regulations and Approvals 1..................
Personal Safety 2............................
Fire Safety 2................................
Grounding 3.................................
Action in the Event of a Malfunction 3...........
Disposal 3..................................
Description 5..................................
Specifications 6..............................
Dimensions and Weights 6.................
Serial Number Label 6.....................
Installation 7..................................
Standard Articulated Bar Mount Kit 7...........
Optional Articulated and Fixed Gun
Bar Mount Kits 8.............................
Gun Connections 9..........................
Optional Ion Collector Installation 10.............
Adjusting the Ion Collector Rod 10............
Changing From Conical to Flat
or Corner Spray Nozzle 12.....................
Operation 14...................................
Cleaning Conical Nozzles and Deflectors 14......
Cleaning Flat and Corner Spray Nozzles 16.......
Maintenance 17.................................
Daily Maintenance 17..........................
Weekly Maintenance 18.......................
Troubleshooting 19.............................
General Troubleshooting Chart 19...............
Power Supply Resistance Test 22...............
Electrode Support Resistance Test 22...........
Cable Continuity Tests 23......................
Gun Receptacle Harness 23................
Gun Extension Cable 23....................
Standard Gun Cables 24....................
Repair 25......................................
Preparation 25................................
Replacing the Powder Tube 25.................
Replacing the Power Supply 26.................
Electrode Support Sleeve Replacement
XD Version 29................................
Electrode Support Sleeve Replacement
SD Version 30................................
Parts 32.......................................
Spray Gun 32.................................
Electrode Support Assemblies 34................
Cables 35....................................
Optional Flat and Corner Spray Nozzles 36.......
Standard Articulating Gun Bar 37...............
Optional Articulating Gun Bar 38................
Optional Fixed Gun Bar 39.....................
Optional Ion Collector Kit 40
....................
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 2018. 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, Nordson, and the Nordson logo are registered trademarks of
Nordson Corporation.
All other trademarks are the properties of their respective owners.

Change Record i
Part 1612502−01
E2018 Nordson Corporation
Change Record
Revision Date Change
01 8/18 New Release

Change Record
ii
Part 1612502−01 E2018 Nordson Corporation

EncorerAutomatic PE Powder Spray Gun 1
Part 1612502−01
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EncorerAutomatic PE Powder Spray Gun
Safety
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.

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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 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.

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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.

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Description
The Encore Automatic Porcelain Enamel (PE) Powder Spray Gun
electrostatically charges and sprays porcelain enamel (frit) powder coatings.
The gun is equipped with a 100 kV integral electrostatic power supply and
electrode air-wash to prevent powder from collecting on the electrode. The
guns have a straight-through powder path to minimize impact fusion.
The guns are used with the Nordson Encore iControl System or Encore LT
Automatic Controllers, which provide electrostatic voltage control, electrode
air-wash air, and powder pump air.
A ceramic conical nozzle and 38-mm deflector is shipped with the gun.
Optional equipment includes:
S8, 12, and 16-meter (26, 39, 52-ft) control cables.
S4-meter (13 ft) extension cable
S4-ft (121 cm) fixed or articulating bar mounts.
Sion collector kit.
S4 and 6-mm flat spray nozzles.
S4 and 6-mm corner spray nozzles.
2
1
3
4
6
7
5
Figure 1 Encore Automatic PE Powder Spray Gun with Conical Nozzle
1. Conical deflector
2. Conical pattern adjuster
3. Nozzle nut
4. Gun body
5. Mounting bracket
6. Tube adapter
7. Powder hose adapter

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Specifications
Input Rating Output Rating
+/−19 VAC, +/−1 A (Peak) 100 KV, 100 μA
SAir Quality: <5μparticulates, dew point <10 _C (50 _F)
SMax Relative Humidity: 95% non-Condensing
SAmbient Temperature Rating: +15 to +40 _C (59−104 _F)
SThis applicator is used with Porcelain Enamel powders which are
non-flammable.
Dimensions and Weights
13 cm (5.30 in.)
0.4 cm (0.16 in.)
5.8 cm (2.28 in.)
37 cm (14.57 in.) to pivot center
40.4 cm (15.93 in.)
39.7 cm (15.62 in.)
Encore PE Bar-Mount Gun
Weight: 897 grams (1.98 lbs)
6.9 cm (2.72 in.)
7.0 cm (2.77 in.)
∅6.1 cm (2.40 in.)
Figure 2 Gun Dimensions and Weights (with Conical Nozzle)
Serial Number Label
NOTE: The gun serial number contains the location, year, and month it was
manufactured. The serial number starts with “AA10A”. The “AA” means the
product was built in Amherst, Ohio, the “10” meaning the year 2010. The
“A” means the month of January, “B” would be February, and so on.
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1602042−02

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Installation
Standard Articulated Bar Mount Kit
1. See Figure 3. Install the tube adapter (3) into the end of the adjusting
rod (9) and secure it by tightening the set screw (10) with a 4-mm hex
key.
STo move the gun tip from side to side, loosen the right button screw (1).
STo tilt the gun tip up or down, loosen the tilt knob (4).
STo rotate the adjusting rod or slide the adjusting rod forward or back,
loosen the locking handle (5).
2. Position the clamp (7) on a 1 inch mounting bar and tighten the clamp
handle (6).
3. Bundle the powder hose, 4-mm clear electrode air-wash tubing, and gun
cable together and secure them to the adjusting rod with Nordson Velcro
straps. Connect them to the spray gun as shown in Figure 5.
5
9
7
8
1
2
3
4
10
6
1
Figure 3 Standard Articulated Bar-Mount Gun Mounting
1. Button screws
2. Tilt bracket
3. Tube adapter
4. Tilt knob
5. Locking handle
6. Clamp handle
7. Clamp
8. Locking body
9. Adjusting rod
10. Set screw

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Optional Articulated and Fixed Gun Bar Mount Kits
See Figure 4. These optional bar mount kits have large inner diameter
adjusting rods (1), through which the powder hose, air tubing, and gun cable
can be routed. The tube adapter (2) shipped with the spray gun cannot be
used with these kits. It must be exchanged for the tube adapter provided
with the kits.
1. Unscrew and remove the knob and washer (5, 4) from the gun mounting
bracket (3).
2. Remove the standard tube adapter (not shown) from the gun mounting
bracket.
3. Slide the end of the optional tube adapter (2) into the gun mounting
bracket and align the hole in the end of the tube adapter with the holes
in the gun mounting bracket.
4. Install the knob and washer through the mounting bracket and tighten.
5. See Figure 5. Pull (in the following order) the gun cable, 4-mm clear
electrode air-wash tubing, and powder hose through the end mounting
tube and out the cutout. Connect them to the spray gun as shown in
Figure 5.
1
1
5 4 3
2
2
5 4 3
Articulating Bar Mount
Fixed Bar Mount
Figure 4 Optional Gun Bar Mount Kits
1. Adjusting rod
2. Tube adapter
3. Bar mount bracket
4. Washer
5. Knob

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Gun Connections
1. Connect the powder hose (1) to the hose connector and secure the
hose with a hose clamp (4).
2. Connect the 4-mm clear electrode air-wash tubing (2) to the barbed
fitting.
3. Connect the gun cable (3) to the receptacle and tighten the cable nut
securely.
Standard Bar Mount Connections
Optional Bar Mount Connections
1 3
2
13
24
4
Figure 5 Gun Connections
1. Powder hose
2. Electrode air wash tubing
3. Gun cable 4. Hose clamp

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Optional Ion Collector Installation
The ion collector collects ions emitted from the gun’s charging electrode
instead of allowing them to deposit on the part. This reduces the rate of
charge buildup in the powder deposited on the part, which may reduce
defects in the cured coating such as pinholing and orange peel, and can
improve the smoothness and appearance of cured powder coatings.
After installing the ion collector, adjust the collector rod position for best
results as described in Adjusting the Ion Collector Rod.
1. See Figure 6. Install the mounting block (1) on the gun with the M5
lockwasher and screw (2, 3).
2. Insert the collector rod (5) into the block and secure it with the M5 x 8
set screw (4) included in the ion collector kit.
3. Slide the multi-point tip (6) onto the nozzle nut and attach it to the
collector rod with the M3 screw (7).
NOTE: Remove the pattern adjust sleeve from the conical nozzle before
installing the multi-point tip.
1
6
4
5
7
2 3
Figure 6 Ion Collector Installation −Flat Spray Nozzle Shown
Adjusting the Ion Collector Rod
Use this procedure to find the optimum position of the multi-point tip for the
application.
SIf the ion collector tips are too far away from the tip of the electrode, the
ion collector will not collect any ions or improve the appearance of the
cured coating.
SIf the ion collector tips are too close to the tip of the electrode, powder
particles may not be charged efficiently and the powder transfer
efficiency may be reduced.
1. Before installing the ion collector rod on the gun, coat several parts.
Note the current (μA) shown on the control unit display when coating the
parts. Cure the coatings.
2. Install the ion collector kit on the gun.

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3. Loosen the set screw (4) and move the multi-point tip away from the
front end of the gun.
4. Turn on the electrostatic voltage and spray powder with a part in front of
the gun. Slide the rod forward until the current shown on the control unit
display is 5 to 7 μA higher than that displayed in step 1. Tighten the set
screw.
5. Cure the coating on the test parts. Compare the surface finish on these
parts with the finish on the parts coated in step 1 (before the ion
collector kit was installed).
6. If the desired improvement in the surface finish has not been obtained,
loosen the set screw and slide the rod forward approximately 1-in.
Tighten the set screw.
7. Repeat step 5 until the desired improvement in surface finish is
obtained.

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Changing From Conical to Flat or Corner Spray Nozzle
WARNING: Turn off the spray gun and ground the electrode before
performing this procedure. Failure to observe this warning could result in a
severe electrical shock.
CAUTION: The deflector cap (1) and deflector (2) must be removed before
removing the nozzle nut from the spray gun. If they are not removed first,
the electrode support (8) could be subjected to damage and may have to be
replaced.
See Figure 7. To change from the standard conical nozzle to a flat or corner
spray nozzle, the following items should be ordered:
Sthe applicable nozzle (9)
Sa new nozzle nut (5)
Sa flat spray electrode holder kit (items 7, 10, and 11).
Refer to Parts section of this manual for optional nozzles, nozzle nut, and
electrode holder kit.
1. With finger, hold the deflector (2) from turning while unscrewing the
deflector cap (1).
2. Pull the deflector (2) off the conical electrode holder (6).
3. Unscrew the nozzle nut (5) and remove it along with the pattern adjuster
sleeve (3) and conical nozzle (4) from the spray gun.
4. Remove the electrode support assembly (6, 7, and 8) from the spray
gun. Use low-pressure compressed air to clean the assembly. Inspect
for wear and damage. Refer to Electrode Support Assembly
Replacement in the Repair section of this manual.
5. Unscrew the conical electrode holder (6) from the electrode support (8)
6. Install the 6 mm ID x 20 mm long polyurethane wear sleeve (10) over
the end of the flat electrode holder (11).
7. Insert the new electrode (7) into the flat electrode holder (11).
8. Screw the flat electrode holder into the electrode support. Install the
electrode support assembly (7, 8, 10, and 11) into the spray gun.
9. Install the flat spray or corner spray nozzle (9) onto the electrode
support (8), then install the new nozzle nut on the spray gun.

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Changing From Conical to Flat or Corner Spray Nozzle (contd)
12
34
5
6
5
7
8
11
9
7
10
8
Conical Style Nozzle
Flat Spray Nozzle Shown
Figure 7 Changing From Conical to Flat or Corner Spray Nozzle (shown with Flat Spray Nozzle).
1. Deflector cap
2. Deflector
3. Pattern adjuster sleeve
4. Conical nozzle
5. Nozzle nut
6. Conical electrode holder
7. Electrode
8. Electrode support assembly
(XD Shown)
9. Flat spray nozzle
10. Wear sleeve
11. Flat electrode holder

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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.
Automatic and manual control of electrostatic output, air-wash air flow, and
pump air flow, are provided by the Nordson iControl System or the Encore
LT Automatic Controllers. spray gun triggering and positioning are provided
by the iControl System, a Nordson Axis Controller, or a PLC supplied either
by Nordson or the customer. Refer to your controller manual for
programming information and instructions.
Cleaning Conical Nozzles and Deflectors
WARNING: Turn off the spray gun and ground the electrode before
performing this procedure. Failure to observe this warning could result in a
severe electrical shock.
WARNING: Release the spray gun trigger, put the controller to sleep, and
ground the electrode before performing this procedure. Failure to observe
this warning could result in a severe electric shock.
CAUTION: Purge the spray gun and press the Enable/Disable button to put
the controller to sleep and prevent accidental spray gun triggering.

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CAUTION: The deflector cap (1) and the deflector (2) must be removed
before removing the nozzle nut from the spray gun. If they are not removed
first, the electrode support (8) could be subjected to damage and may have
to be replaced.
1. See Figure 8. Hold the deflector (2) with finger while unscrewing the
deflector cap (1). Gently pull the deflector (2) off the conical electrode
holder (6).
2. Unscrew the nozzle nut (5) counterclockwise and remove the nut,
conical nozzle (4) and pattern sleeve (3) from the spray gun.
3. Remove the electrode support assembly (6, 7, and 8) from the spray
gun. Use low-pressure compressed air to clean the assembly. Inspect
the assembly for wear or damage. Refer to the Electrode Support
Assembly Replacement instructions in the Repair section of this manual.
4. Clean all parts with low-pressure compressed air. Inspect all parts and
replace any that are worn or damaged.
5. Inspect the electrode holder (6). If the electrode support is worn or
damaged, unscrew it from the electrode support (8), then remove the
electrode (7). Install the electrode in the new holder, then screw the
holder into the electrode support. Install the electrode support assembly
(6, 7, and 8) into the spray gun
6. Screw the nozzle nut onto the spray gun.
7. Install the deflector onto the electrode holder. Do not bend the end of the
electrode.
8. Screw the deflector cap onto the electrode holder tight.
NOTE: Press the Enable/Disable button to wake up the controller and
resume the operation.
1
2
4
5
67
8
3
Figure 8 Cleaning a Conical Nozzle
1. Deflector cap
2. Deflector
3. Pattern sleeve
4. Conical nozzle
5. Nozzle nut
6. Electrode holder (See Note)
7. Electrode
8. Electrode support assembly
(XD Shown)
Note: The electrode holder used with a Conical spray nozzle is not interchangeable with Flat/Corner spray nozzles.

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Cleaning Flat and Corner Spray Nozzles
WARNING: Release the spray gun trigger, put the controller to sleep, and
ground the electrode before performing this procedure. Failure to observe
this warning could result in a severe electric shock.
WARNING: Turn off the spray gun and ground the electrode before
performing this procedure. Failure to observe this warning could result in a
severe electrical shock.
CAUTION: Purge the spray gun and press the Enable/Disable button to put
the controller to sleep and prevent accidental spray gun triggering.
1. See Figure 9. Unscrew the nozzle nut (1) counterclockwise
2. Pull the nozzle nut (1) and nozzle (2) off the spray gun. Remove the
nozzle from the nut and clean both with low-pressure compressed air
and clean cloths. Replace if worn or damaged.
3. Remove the electrode support assembly (3, 4, 5, and 6) from the spray
gun. Use low-pressure compressed air to clean the assembly. Inspect
the assembly and replace it if worn or damaged. Refer to the Electrode
Support Assembly Replacement in the Repair section of this manual.
4. Inspect the wear sleeve (3) and the electrode holder (4). If either is worn
or damaged, replace them with the flat spray electrode holder kit.
a. Unscrew the electrode holder and sleeve from the electrode support
assembly (6).
b. Install the new sleeve (3) over the new electrode holder (4).
c. Install the electrode (5) in the new holder, then screw the holder into
the electrode support assembly (6).
5. Install the electrode support assembly back into the spray gun.
6. Install the nozzle (2) onto the electrode support (4), then screw the
nozzle nut (1) onto the spray gun body clockwise until finger tight.
NOTE: Press the Enable/Disable button to wake up the controller and
resume operation.
12
4
56
3
Figure 9 Cleaning a Flat/Corner Spray Nozzle
1. Nozzle nut
2. Flat spray nozzle
3. Wear sleeve
4. Electrode holder (See Note)
5. Electrode
6. Electrode support assembly
(XD Shown)
Note: The electrode holder used with a Flat/Corner spray nozzle is not interchangeable with a Conical spray nozzle.