Nordson Encore Select HD Reference guide

Encore®Select HD
Robot Gun
Customer Product Manual
Document Number1620445-03
Issued 01/22
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.
NORDSON CORPORATION • AMHERST, OHIO • USA

© 2022 Nordson Corporation
1620445-03
Contact Us
Nordson Corporation welcomes requests for information, comments, and inqui-
ries 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 2020. 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 property of their respective owners.

i
Table of Contents
©2022 Nordson Corporation 1620445-03
Safety ............................................................................................................................................. 1-1
Introduction................................................................................................................................... 1-1
Qualied 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
Overview........................................................................................................................................ 2-1
Introduction.................................................................................................................................... 2-1
Specications................................................................................................................................. 2-2
Dimensions and Weights.............................................................................................................. 2-2
Equipment Markings...................................................................................................................... 2-3
Applicator Certication Marking.................................................................................................... 2-3
Serial Number Marking................................................................................................................. 2-3
European Union, ATEX, Special Conditions for Safe Use............................................................. 2-3
System Connections...................................................................................................................... 3-1
Spray Gun Installation .................................................................................................................. 3-2
Dual Spray Gun System Connections.......................................................................................... 3-3
Encore Controller Interface Conguration Settings ...................................................................... 3-4
iFlow® PCA Conguration Settings ............................................................................................... 3-4
Daily Operation.............................................................................................................................. 4-2
Initial Startup................................................................................................................................. 4-2
Startup.......................................................................................................................................... 4-2
Standby Button............................................................................................................................. 4-2
Electrode Air Wash Operation ....................................................................................................... 4-3
Changing Flat Spray Nozzles....................................................................................................... 4-3
Converting from Flat Spray Nozzles to Optional Conical Nozzles................................................ 4-4
Changing Optional Deectors or Conical Nozzles........................................................................ 4-5
Installing the Optional Pattern Adjuster Kit ................................................................................... 4-6
Shutdown....................................................................................................................................... 4-7
Maintenance .................................................................................................................................. 4-7
Recommended Cleaning Procedure for Powder Contact Parts ................................................... 4-7
Maintenance Procedures.............................................................................................................. 4-8
Repair............................................................................................................................................. 5-1
Spray Gun Repair.......................................................................................................................... 5-1
Power Supply and Powder Path Replacement............................................................................. 5-2
Spray Gun Disassembly.............................................................................................................. 5-2
Power Supply Replacement........................................................................................................ 5-3
Powder Path Removal................................................................................................................. 5-4
Powder Path Installation.............................................................................................................. 5-4
Spray Gun Re-Assembly............................................................................................................. 5-5
Table of Contents

©2022 Nordson Corporation
1620445-03
ii Table of Contents
Troubleshooting............................................................................................................................ 6-1
General Troubleshooting Chart...................................................................................................... 6-1
Spray Gun Power Supply Resistance Test .................................................................................... 6-4
Electrode Assembly Resistance Test............................................................................................. 6-5
Cable Continuity Test..................................................................................................................... 6-5
Gun Cable Receptacle Harness................................................................................................... 6-5
Gun Extension Cable .................................................................................................................. 6-6
Robot Gun Cable......................................................................................................................... 6-6
Parts............................................................................................................................................... 7-1
Introduction.................................................................................................................................... 7-1
Reference Documentation............................................................................................................ 7-1
Spray Gun Parts ............................................................................................................................ 7-2
Spray Gun Parts List .................................................................................................................... 7-3
Powder Hose and Air Tubing........................................................................................................ 7-4
Spray Gun Options ........................................................................................................................ 7-4
Cables .......................................................................................................................................... 7-4
Spray Gun Options (contd)............................................................................................................ 7-5
Optional Nozzles .......................................................................................................................... 7-5
45-Degree Corner-Spray Nozzle.................................................................................................. 7-6
45-Degree Flat-Spray Nozzle....................................................................................................... 7-6
Conical Nozzle, Deectors, and Electrode Assembly Parts ......................................................... 7-7
Conical Nozzle and Deectors .................................................................................................... 7-7
Conical Nozzle Kit ....................................................................................................................... 7-7
Conical Nozzle, Deectors and Electrode Assembly Parts (contd) ............................................. 7-8
Conical Electrode Assembly........................................................................................................ 7-8
XD Electrode Support................................................................................................................... 7-8
Pattern Adjuster Kit....................................................................................................................... 7-9
Ion Collector Kit ............................................................................................................................ 7-9
Dual Spray Gun System Components........................................................................................ 7-10

i
Change Record
©2022 Nordson Corporation 1620445-03
Change Record
Revision Date Change
01 11/20 Initial Release
02 02/21 Updated spray gun markings and safety information.
03 01/22 Updated approvals information, corrected reference text, and updated power supply
test image.

©2022 Nordson Corporation
1620445-03
ii Change Record

1-1
Safety
© 2022 Nordson Corporation 1620445-03
Section 1
Safety
Introduction
Read and follow these safety instructions. Task- and equipment-specic warnings,
cautions, and instructions are included in equipment documentation where appropriate.
Make sure all equipment documentation, including these instructions, is accessible to
persons operating or servicing equipment.
Qualied Personnel
Equipment owners are responsible for making sure that Nordson equipment is installed,
operated, and serviced by qualied personnel. Qualied 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:
• using incompatible materials
• making unauthorized modications
• removing or bypassing safety guards or interlocks
• using incompatible or damaged parts
• using unapproved auxiliary equipment
• operating 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.

© 2022 Nordson Corporation
1620445-03
1-2 Safety
Personal Safety
To prevent injury follow these instructions.
• Do not operate or service equipment unless you are qualied.
• Do 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.
• Keep clear of moving equipment. Before adjusting or servicing any moving equipment,
shut o󰀨 the power supply and wait until the equipment comes to a complete stop. Lock
out power and secure the equipment to prevent unexpected movement.
• Relieve (bleed o󰀨) hydraulic and pneumatic pressure before adjusting or servicing
pressurized systems or components. Disconnect, lock out, and tag switches before
servicing electrical equipment.
• Obtain and read Material 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.
• To 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 re or explosion, follow these instructions.
• Ground all conductive equipment. Use only grounded air and uid hoses. Check
equipment and workpiece grounding devices regularly. Resistance to ground must not
exceed one megohm.
• Shut down all equipment immediately if you notice static sparking or arcing. Do not
restart the equipment until the cause has been identied and corrected.
• Do not smoke, weld, grind, or use open ames where ammable materials are being
used or stored. Do not heat materials to temperatures above those recommended
by the manufacturer. Make sure heat monitoring and limiting devices are working
properly.
• Provide adequate ventilation to prevent dangerous concentrations of volatile particles
or vapors. Refer to local codes or your material SDS for guidance.
• Do not disconnect live electrical circuits when working with ammable materials. Shut
o󰀨 power at a disconnect switch rst to prevent sparking.
• Know where emergency stop buttons, shuto󰀨 valves, and re extinguishers are
located. If a re starts in a spray booth, immediately shut o󰀨 the spray system and
exhaust fans.
• Shut o󰀨 electrostatic power and ground the charging system before adjusting,
cleaning, or repairing electrostatic equipment.
• Clean, maintain, test, and repair equipment according to the instructions in your
equipment documentation.
• Use only replacement parts that are designed for use with original equipment. Contact
your Nordson representative for parts information and advice.

© 2022 Nordson Corporation 1620445-03
1-3
Safety
Grounding
WARNING:Operating faulty electrostatic equipment is hazardous and can cause
electrocution, re, or explosion. Make resistance checks part of your periodic mainte-
nance 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 identied 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.
• All 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.
• Equipment to be grounded includes, but is not limited to, the oor of the spray area,
operator platforms, hoppers, photoeye supports, and blow-o󰀨 nozzles. Personnel
working in the spray area must be grounded.
• There 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.
• Operators 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 ngers, wear electrically conductive gloves, or
wear a grounding strap connected to the gun handle or other true earth ground.
• Shut o󰀨 electrostatic power supplies and ground gun electrodes before making
adjustments or cleaning powder spray guns.
• Connect 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 o󰀨 the system immediately
and perform the following steps:
• Disconnect and lock out system electrical power. Close hydraulic and pneumatic
shuto󰀨 valves and relieve pressures.
• Identify the reason for the malfunction and correct it before restarting the system.
Disposal
Dispose of equipment and materials used in operation and servicing according to local
codes.

© 2022 Nordson Corporation
1620445-03
1-4 Safety

2-1
Overview
© 2022 Nordson Corporation 1620445-03
Section 2
Overview
Introduction
See Figure 2-1. This manual details the Encore® Select HD Robot Spray Gun.
The Encore Select HD Robot Spray Gun should be used with the Encore HD manual
controller or Encore Enhance Controller, which provides electrostatic voltage control,
electrode air-wash air, and powder pump air.
Flat spray nozzles with 3-mm slots are shipped with the HD Select spray gun. A conical
nozzle kit that contains a conical nozzle, a 26-mm deector and a conical electrode
holder is available as an option. Use the conical nozzle kit to convert from at spray to
conical spray applications.
See Spray Gun Options in the Parts section for information on additional options.
Figure 2-1 Encore Select Robot Spray Gun

© 2022 Nordson Corporation
1620445-03
2-2 Overview
Specications
Model: Encore Applicator
Input Rating: +/- 19 VAC, 1 A
Output Rating: 100 KV, 100 µA
Input Air: 6.0-7.6 bar (87-110 psi), <5µ particulates,
dew point <10 °C (50 °F)
Max Relative Humidity: 95% non-Condensing
Ambient Temperature Rating: +15 to +40 °C
(59-104 °F)
Hazardous Location Rating for Applicator: Zone 21 or Class II, Division 1
Dust Ingress Protection: IP6X
Dimensions and Weights
[6.390]
162.3
[12.236]
310.8
[3.576]
90.8
C.G.
[6.745]
171.3
[7.342]
186.5
[2.126]
54.0
[.709]
18.0 2X M5X0.8 - 6H ↓ 8.0
Encore Select HD Robot Spray Gun
Weight: [1.07 lb] 486 g
[.255]
6.5
C.G.
[1.929]
49.0
75°
Figure 2-2 Encore Select HD Robot Spray Gun Dimensions and Weights

© 2022 Nordson Corporation 1620445-03
2-3
Overview
Equipment Markings
Applicator Certication Marking
Figure 2-3 Applicator Certication Marking
Serial Number Marking
The spray gun serial number contains the location, year, and month it was manufactured.
The serial number starts with “AA20A”. The “AA” signies that the product was built in
Amherst, Ohio, the “20” representing the year of manufacture, 2020. The “A” means the
month of January, “B” would mean February, and so on through “L”, or December.
Figure 2-4 Encore Select HD Serial Number
European Union, EX, Special Conditions for Safe Use
1. The Encore Select HD Robot Spray Gun shall only be used with the associated
Encore XT/HD interface control unit and Encore HD controller power unit, or the
Encore Enhance controls, over the ambient temperature range of +15 °C
to +40 °C.
2. Caution should be taken when cleaning external painted and non-metallic surfaces of
the controller, interface, applicator, and all accessories. There is a potential for static
electricity build up on these components. Follow the manufacturer’s instructions to
avoid possible electrostatic charging hazards. Guidance on protection against the risk
of ignition due to electrostatic discharge can be found in PD CLC/TR 60079-32-1 and
IEC TS 60079-32-1.

© 2022 Nordson Corporation
1620445-03
2-4 Overview

3-1
Setup
© 2022 Nordson Corporation 1620445-03
Section 3
Setup
System Connections
WARNING:This diagram does not show system grounds. All conductive equipment in
the spray area must be connected to a true earth ground.
Robot Spray Gun
Pump Control Unit
Manual System
Controller
Gun Cable
Powder Hose Input6 mm Input
4 mm Input
4 mm Air Wash6 mm Pattern Air
Powder
Hose
Network/Power
Interconnect
Figure 3-1 System Diagram (Common System Equipment Shown)

© 2022 Nordson Corporation
1620445-03
3-2 Setup
Spray Gun Installation
See Figure 3-2 and Figure 3-3 for spray gun connection illustrations.
1. Connect the 6-mm pattern air tubing to the quick-disconnect tting (1) in the gun base.
Connect the other end to the pattern air tubing on the tting located on the pump
control unit.
2. Connect the 4-mm clear electrode air wash tubing to the quick-disconnect tting (4) in
the bottom of the gun base. Connect the other end to the electrode air wash tubing on
the 90° ow control tting on top of the pump control unit.
3. Connect the powder hose over the barbed end of the hose connector (2).
4. Connect the gun cable to the gun cable receptacle (3).
5. Route the powder hose, gun cable, and air tubing to the system controller. Take care
to not kink, bind, or deform the powder tubing.
1
3
2
4
Figure 3-2 Spray Gun Connections

© 2022 Nordson Corporation 1620445-03
3-3
Setup
Dual Spray Gun System Connections
WARNING:This diagram does not show system grounds. All conductive equipment in
the spray area must be connected to a true earth ground.
NOTE:Refer to manual 1604870, Encore HD and XT Manual Powder Spray System
Controller for more information about the controller.
Figure 3-3 shows a typical dual robot spray gun system and the connections required for
CAN communication between the Encore Controller Interface and the customer PLC.
Conguration of the Encore Controller Interface and the iFlow®module PCA inside the
Encore HD pump control unit must be completed during system installation.
See table on page 7-10 for system component part numbers.
AFC
STD
M /HR
uA
GUN CONTROL
Encore
TM
3
KV
SCFM
%
AFC
STD
M /HR
uA
GUN CONTROL
Encore
TM
3
KV
SCFM
%
1
1
2
2
4
4
8
8
5
6
5
7
5
6
5
7
Power
Power
iFlow Module
PCA
3
Customer PLC
(Drop) (Drop)
Terminate Terminate
F F
M
F
F
M
Power
Figure 3-3 Connections for 2 Spray Gun Robot Systems
1. Encore Select HD Robot spray gun
2. Encore controller interface
3. Control unit, PLC gateway
4. Encore robot cable
5. Controller interface cable
6. DeviceNet 5-pin cable Tee
7. Encore HD pump control unit
8. Network cable

© 2022 Nordson Corporation
1620445-03
3-4 Setup
Encore Controller Interface Conguration Settings
NOTE:Refer to manual 1604870, Encore HD and XT Manual Powder Spray System
Controller, for more information about the controller.
See Figure 3-3. Each Encore controller interface (2) must be congured with the function
codes set to the values listed in Table 3-1 for each spray gun in a dual robot spray gun
system.
Table 3-1 Encore Controller Function Code Values
Function Code Spray Gun 1 Spray Gun 2
F00 02 (Robot) 02 (Robot)
F17 10 (Presets) 10 (Presets)
F18 01 (HDLV) 01 (HDLV)
F19 01 (EXT) 01 (EXT)
F20 01 (GUN) 02 (GUN)
iFlow® PCA Conguration Settings
The following switch settings and CAN network jumper settings must be set to the values
listed in Table 3-2 for each of the spray guns in a dual robot spray gun system.
Table 3-2 Encore Controller Function Code Values
Robot Spray Gun Address Switch Value
Spray Gun 1 SW2=1
Spray Gun 2 SW2=2
1. See Figure 3-3. Access the iFlow PCA inside the Encore HD pump control unit (7).
2. See Figure 3-4. The address switch SW2 must be set to the spray gun number that it
is supplying.
3. If the Encore HD pump control unit (7) is connected to the Nordson CAN network on
the drop, then the network terminator on JP1 must be removed on each of the pump
control units.
NOTE:Each drop on the CAN network is limited to 6 m (20 ft) maximum.

© 2022 Nordson Corporation 1620445-03
3-5
Setup
Network Terminator JP1
Addressing Switch SW2
Figure 3-4 iFlow Module PCA

© 2022 Nordson Corporation
1620445-03
3-6 Setup