Nordson Encore Reference guide

EncorerAutomatic Porcelain
Enamel HD Powder Spray Gun
Customer Product Manual
Part 1605438-04
Issued 08/16
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 for the latest version.

Part 1605438-04 E2016 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, iFlow, Nordson and the Nordson logo are registered
trademarks of Nordson Corporation.
All other trademarks are the property of their respective owners.

Change Record i
Part 1605438-04
E2016 Nordson Corporation
Change Record
Revision Date Change
02 05/15 Updated serial number label.
03 08/15 Change made to Parts section
04 08/16 Added power supply kits

Change Record
ii
Part 1605438-04 E2016 Nordson Corporation

Table of Contents iii
Part 1605438-04
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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.............................................
Specifications 2-2.........................................
Dimensions and Weight 2-2..............................
Serial Number Label 2-2.................................
Installation 3-1..............................................
Standard Articulated Bar Mount Kit 3-2......................
Optional Articulated and Fixed Gun Bar Mount Kits 3-3........
Gun Connections 3-4......................................
Optional Ion Collector Installation 3-5........................
Adjusting the Ion Collector Rod 3-5........................
Changing From Conical to Flat or Corner Spray Nozzle 3-6.....
Operation 4-1...............................................
Maintenance 5-1............................................
Daily Maintenance 5-1.....................................
Weekly Maintenance 5-1...................................
Troubleshooting 6-1.........................................
General Troubleshooting Chart 6-2..........................
Power Supply Resistance Test 6-5..........................
Electrode Support Resistance Test 6-5.......................
Cable Continuity Tests 6-6.................................
Gun Receptacle Harness 6-6............................
Gun Extension Cable 6-6................................
Standard Gun Cables 6-7...............................
Repair 7-1..................................................
Preparation 7-1...........................................
Replacing the Powder Tube 7-1.............................
Replacing the Power Supply 7-2.............................
Electrode Support Sleeve Replacement 7-5..................

Table of Contents
iv
Part 1605438-04 E2016 Nordson Corporation
Parts 8-1...................................................
Introduction 8-1.............................................
Using the Illustrated Parts List 8-1...........................
Spray Gun Parts Illustration 8-2.............................
Spray Gun Parts List 8-3...................................
External Diffuser Repair Kits 8-4.............................
External Diffuser Kit 8-4.................................
Housing Assembly Kit 8-4...............................
Adapter Assembly Kit 8-5................................
Electrode Support Repair Parts 8-5..........................
Options 9-1.................................................
Cables 9-1...............................................
Optional Flat and Corner Spray Nozzles 9-2..................
Standard Articulating Gun Bar 9-3...........................
Optional Articulating Gun Bar 9-4...........................
Optional Fixed Gun Bar 9-5................................
Optional Ion Collector Kit 9-6...............................

Safety 1-1
Part 1605438-04
E2016 Nordson Corporation
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
1-2
Part 1605438-04 E2016 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
Part 1605438-04
E2016 Nordson Corporation
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
1-4
Part 1605438-04 E2016 Nordson Corporation

Description 2-1
Part 1605438-04
E2016 Nordson Corporation
Section 2
Description
The EncorerAutomatic Porcelain Enamel (PE) HD Powder Spray Gun
electrostatically charges and sprays porcelain enamel (frit) powder coatings.
The guns are used with the Nordson Encore iControleSystem or Encore HD
manual controllers for robot applicaitons, which provide electrostatic voltage
control, electrode air-wash air, and powder pump air.
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.
A ceramic conical nozzle and a 38-mm deflector are 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 2-1 Encore Automatic PE HD 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

Description
2-2
Part 1605438-04 E2016 Nordson Corporation
Specifications
Input Rating Output Rating
+/−19 VAC, +/−1 A (Peak) 100 KV, 100 A
SAir Quality: <5particulates, 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 Weight
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.)
42.2 cm (16.62 in.)
Encore PE HD 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 2-2 Gun Dimensions and Weight (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” indicates
that the product was built in Amherst, Ohio. The “10” indicates the year
2010. The final letter “A” indicates the month of January, “B” would be
February, and so on.
ÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎ
1605721−02

Installation 3-1
Part 1605438-04
E2016 Nordson Corporation
Section 3
Installation
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.

Installation
3-2
Part 1605438-04 E2016 Nordson Corporation
Standard Articulated Bar Mount Kit
1. See Figure 3-1. 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 3-3.
5
9
7
8
1
2
3
4
10
6
1
Figure 3-1 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

Installation 3-3
Part 1605438-04
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Optional Articulated and Fixed Gun Bar Mount Kits
See Figure 3-2. The 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 3-3. 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 3-3.
1
1
5 4 3
2
2
5 4 3
Articulating Bar Mount
Fixed Bar Mount
Figure 3-2 Optional Gun Bar Mount Kits
1. Adjusting rod
2. Tube adapter
3. Bar mount bracket
4. Washer
5. Knob

Installation
3-4
Part 1605438-04 E2016 Nordson Corporation
Gun Connections
See Figure 3-3.
1. Connect the powder hose (1) to the hose adapter (5).
2. Connect the 4-mm clear electrode air-wash tubing (2) to the barbed
fitting (6).
3. Connect the gun cable (3) to the receptacle and tighten the cable nut
securely.
4. Connect the atomizing air tubing (4) to the atomizing air fitting, as
shown.
1
25
4
3
Standard Bar Mount Connections
3
125
4
Optional Bar Mount Connections
6
6
Figure 3-3 Gun Connections −Conical Nozzle Shown
1. Powder hose
2. Electrode air wash tubing
3. Gun cable
4. Atomizing air tubing
5. Hose adapter
6. Barbed fitting

Installation 3-5
Part 1605438-04
E2016 Nordson Corporation
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 3-4. Install the mounting block (1) on the gun with the M5
lock washer 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 3-4 Ion Collector Installation −Flat Spray Nozzle Shown
1. Mounting block
2. Lock washer
3. M5 screw
4. M5 x 8 set screw
5. Collector rod
6. Multi-point tip
7. M3 screw
Adjusting the Ion Collector Rod
Use this procedure to find the optimum position of the multi-point tip for the
application.
NOTE: If 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.
NOTE: If 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.

Installation
3-6
Part 1605438-04 E2016 Nordson Corporation
Adjusting the Ion Collector Rod (contd)
1. Before installing the ion collector rod on the gun, coat several parts.
Note the current (A) shown on the control unit display when coating the
parts. Cure the coatings.
2. Install the ion collector kit on the gun.
3. See Figure 3-4. 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 A 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 this test procedure until the desired improvement in surface
finish is obtained.
Changing From Conical to Flat or Corner Spray Nozzle
See Figure 3-5. To change from the standard conical nozzle to a flat or
corner spray nozzle, you will need to order:
Sthe nozzle desired (8)
Sa new nozzle nut (4)
Sa flat spray electrode holder kit (items 6, 9, and 10).
Refer to page 9-2 for optional nozzles, nozzle nut, and electrode holder kit.
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 gun. If they are not removed first, the
spring (item 2, Figure 7-5) in the electrode support will be damaged and will
have to be replaced.
1. With your finger, hold the deflector (2) from turning while you unscrew
the deflector cap (1) .
2. Pull the deflector off the conical electrode holder (5).
3. Unscrew the nozzle nut (4) and remove it along with the pattern
sleeve (3) and conical nozzle from the gun.
4. Remove the electrode support (7) and clean it with a blow gun.
5. Unscrew the conical electrode holder from the electrode support.

Installation 3-7
Part 1605438-04
E2016 Nordson Corporation
6. Insert the new electrode (6) into the flat electrode holder (10).
7. Screw the flat electrode holder into the electrode support.
8. Install the 6-mm ID x 20-mm long polyurethane wear sleeve (9) over the
end of the flat electrode holder.
9. Install the flat spray or corner spray nozzle (8) into the new nozzle
nut (4), then install the nozzle nut on the spray gun.
1
2
3
4
56
4
7
8
6
9
7
10
Figure 3-5 Changing From Conical to Flat or Corner Spray Nozzle
1. Deflector cap
2. Deflector
3. Pattern sleeve
4. Nozzle nut
5. Conical electrode holder
6. Electrode
7. Electrode support
8. Flat spray nozzle
9. Wear sleeve
10. Flat electrode holder

Installation
3-8
Part 1605438-04 E2016 Nordson Corporation