Nordson HD+ User manual

EncorerHD Pump
Customer Product Manual
Part 1605708−01
Issued 11/17
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.
and available local languages.

Part 1605708−01 E2017 Nordson Corporation
Table of Contents
Safety 1.......................................
Qualified Personnel 1.........................
Intended Use 1..............................
Regulations and Approvals 1..................
Personal Safety 1............................
Fire Safety 2................................
Grounding 2.................................
Action in the Event of a Malfunction 2...........
Disposal 2..................................
Description 3..................................
Pump 3.....................................
Features and Benefits 3....................
Pump Components 4.......................
Theory of Operation 5......................
Pumping 5...............................
Purging 6................................
Stage 1: Soft Purge to Spray Gun 6..........
Stage 2: Soft Purge to Feed Source 6........
Stages 3 and 4: Hard Purge to Spray Gun
and Feed Source 6.........................
Pump Port Functions 7.....................
Manifold 7...................................
Operation 8...................................
Specifications 9...............................
Installation 10..................................
Pump Tubing Installation 10.....................
Standard 8-mm OD Poly Tubing 10...........
Flexible 8-mm OD Tubing 10.................
Pump to Cabinet or Panel 10....................
Maintenance 11................................
Troubleshooting 12.............................
Delivery Check 16..........................
Suction Check 16...........................
Bubble Test for Color-on-Demand (COD
System 17.................................
Repair 18......................................
Fluidizing Tube Replacement 18................
Pump Disassembly 19.........................
Pump Assembly 21...........................
Pinch Valve Replacement 23...................
Pinch Valve Removal 23....................
Pinch Valve Installation 23...................
Parts 26.......................................
Pump 26.....................................
Spare Parts 28.............................
Air and Powder Tubing Part Numbers 29......
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 2017. 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
Color−on−Demand, Encore, 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 1605708−01
E2017 Nordson Corporation
Change Record
Revision Date Change
01 11/17 New publication

Change Record
ii
Part 1605708−01 E2017 Nordson Corporation

EncorerHD Pump 1
Part 1605708−01
E2017 Nordson Corporation
EncorerHD Pump
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, are 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.
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.

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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.
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.

EncorerHD Pump 3
Part 1605708−01
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Description
Pump
See Figure 1. The EncorerHD, HD+, and XD
powder feed pump transports precise amounts of
powder from a feed source to a powder spray gun.
Encore HD+ Encore HD Encore XD
Figure 1 Encore HD Pump Series
Features and Benefits
SStandard pump (HD) has blue pinch valves,
molded Y blocks and standard porous tubes
SHigh flow pump (HD+) is the same as a
standard pump except for high flow spacing
block and high flow porous tubes
SExtreme duty pump (XD) is the same as a
high flow pump except for machine tivar Y
blocks and high temperature pinch valves
SHigher powder output
SImproved uniformity of powder output
SMaintains high reliability of pinch valves
SOne screw maintenance design
SEasier filter replacement
SImproved gasket design
SCentralized wear parts
SOver torque protection

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Pump Components
See Figure 2.
Item Description Function
1Purge Air Fittings and
Check Valves
Route high pressure purge air through the pump. Check valves
prevent powder contamination of the purge valves.
2Fluidizing Tubes Porous cylinders that draw powder into the pump when a
vacuum is applied, and force powder out of the pump when air
pressure is applied.
3Purge Manifold Contains the fluidizing tubes, check valves, and air passages.
4Upper Y Block Interface between the pinch valves and the porous tubes;
consists of two Y-shaped passages that join the inlet and outlet
branches of either half of the pump.
5Pinch Valves Open and close to allow powder to be drawn in or dispensed out
of the fluidizing tubes.
6Pinch Valve Body Houses the pinch valves. Made from clear plastic with metal
thread inserts and ground spring molded in.
7Lower Y Block Connect the inlet and outlet fittings to the pinch valves on either
half of the pump.
8Inlet Fitting Connects to the tubing leading from the power source
9Outlet Fitting Connects to the tubing leading to the powder spray gun
1
5
3
9
4
8
2
7
6
Encore HD Pump
1
2
3
4
7
9
Encore HD+, XD Pump
5
6
8
Figure 2 Encore Pump Components

EncorerHD Pump 5
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Theory of Operation
Pumping
The Encore HD pump consists of two halves that
function identically. The halves alternately draw
powder in and dispense powder out of the pump;
while one half is drawing powder in, the other half
is dispensing powder out.
Left Half Drawing Powder In
See Figure 3.
The left suction pinch valve is open, while the
left delivery pinch valve is closed. Negative air
pressure is applied to the left porous fluidizing
tube, which draws powder in the inlet fitting, up
the left side of the inlet manifold wear block,
through the left suction pinch valve, and into the
left fluidizing tube.
After the negative air pressure has been on for
the specified time, the fluidizing tube’s negative
air pressure shuts off and the left suction pinch
valve closes.
Right Half Dispensing Powder Out
See Figure 4
The right suction pinch valve is closed, while the
right delivery pinch valve is open. Positive air
pressure is applied to the right porous fluidizing
tube, which dispenses the powder out of the
fluidizing tube, down the right delivery pinch
valve, down the right side of the outlet manifold
wear block, out the delivery fitting, and out to the
tubing that leads to the powder spray gun.
As the sides complete these processes, they
alternate. In the example explained above, the left
half would now dispense powder out while the right
half would draw powder in.
As each half dispenses powder out, the powder in
the tubing blends together, resulting in a consistent
flow of powder from the spray gun.
L R
R
L
Left half
suction
valve
open
Right half
delivery
valve
open
Air
Powder
Out
Powder
In
Figure 3 Left Side Drawing In, Right Side Dispensing
NOTE: Illustration is viewed from right rear of the
pump.
Air
Powder
Out
Powder
In
L
R
RL
Right half
suction
valve
open
Left half
delivery
valve
open
Figure 4 Left Side Dispensing, Right Side Drawing In

EncorerHD Pump
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Purging
See Figure 5. When the operator initiates a color
change, the pump goes through a three-stage
purge process.
Stage 1: Soft Purge to Spray Gun
The suction pinch valves close, while the delivery
pinch valves remain open. Pump assist air
pressure turns on, starting at a low pressure and
building up to maximum pump assist pressure.
The air dispenses powder out of both fluidizing
tubes, through the powder delivery tubing and
spray gun and out into the booth.
Stage 2: Soft Purge to Feed Source
The suction pinch valves are open, while the
delivery pinch valves close. Pump assist air
pressure turns on, starting at a low pressure and
building up to maximum pump assist pressure.
The air dispenses powder out of both fluidizing
tubes, through the powder suction tubing, and back
into the powder feed source.
Stages 3 and 4: Hard Purge to Spray Gun
and Feed Source
The delivery pinch valves open. Pump assist air
pressure turns on at maximum pressure, while
pulses of line air pressure are sent down the purge
air fittings at the tops of the fluidizing tubes. The
pulses of air remove any powder that remains in
the pump, spray gun, and suction and delivery
tubing.
After the delivery side is purged, the delivery pinch
valves close and the suction pinch valves open.
The suction side is purged in the same way as the
delivery side.
Air
Powder
Stage 1
Soft Purge to
Powder
Powder
Stage 2
Soft Purge to
Feed Source
Spray Gun
Air
Powder
Stage 3
To Spray Gun
and Feed Source
Stage 4
Air
Hard Purge
Figure 5 Purging Operation

EncorerHD Pump 7
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Pump Port Functions
Figure 6 identifies the functions of the ports on the
rear face of the pump.
Position Function
1Right Side Suction Pinch Valve
2Right Side Delivery Pinch Valve
3Right Side Fluidizing Tube
4Left Side Fluidizing Tube
5Left Side Delivery Pinch Valve
6Left Side Suction Pinch Valve
4
2
1
3
5
6
Figure 6 Pump Port Functions
Manifold
See Figure 7. The Encore High-Density powder,
Low-Volume air (HD) powder feed pump transports
precise amounts of powder from a feed source to a
powder spray gun. The pump control manifold
controls the air flow in and out of the pump.
Manifold is shown for reference only, please refer
to the Encore HD Pump Control Unit and Power
Supply manual for more information.
Position Function
1Right Side Suction Pinch Valve
2Right Side Delivery Pinch Valve
3Right Side Fluidizing Tube
4Left Side Fluidizing Tube
5Left Side Delivery Pinch Valve
6Left Side Suction Pinch Valve
6
1
2
3
4
5
Figure 7 Encore HD Pump Manifold with Port
Functions

EncorerHD Pump
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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.
CAUTION: Do not adjust the regulators
inside the pump cabinet. The regulators
are factory set and should not be
adjusted without guidance from your
Nordson representative.
Pump operation is controlled through the spray gun
controller. Refer to the Operation section of the
Encore Manual Spray Gun Controller manual for
specific instructions.
Pump operation is controlled by specifying a set
point from 0−100 (which translates to a percent of
flow) at the spray gun controller. At the pump, each
set point results in a predefined cycle rate.
Increasing the cycle rate increases the powder
delivery rate. Decreasing the cycle rate decreases
the powder delivery rate.
The manifold also has a spray gun pattern air flow
control valve. spray gun pattern air is controlled by
setting the flow rate (in either scfm or m3/hr) at the
spray gun control unit.
NOTE: When the fluidizing tubes become clogged
with powder, the powder delivery rate decreases
The spray gun controller will generate a fault to
indicate this condition and notify you that it is time
to replace the fluidizing tubes. Correct vacuum
reading is (9−14 in. Hg).

EncorerHD Pump 9
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Specifications
Standard Pump Output (Maximum)
HD: 80 lb/hour (600 g/min.)
HD+, XD: 100 lb/hour (750 g/min.)
Air Consumption
Conveying Air 12.5−31 l/min
(0.438−1.1 scfm)
Gun Pattern Air 6−57 l/min (0.2−2.0 scfm)
Total
Consumption 85−170 l/min (3−6 scfm)
Operating Air Pressures
Pinch Valves 35 psi (2.4 bar)
Flow Control
(to pattern
air/pump assist)
85 psi (5.9 bar)
Vacuum
Generator 50 psi (3.5 bar)
Powder Tubing
Size 8 mm OD x 6 mm ID
Length Output: 20 m (60 ft)
Input: 1−3 m (3.5−12 ft)
70mm
(2.75 in.)
189mm
(7.44 in)
25mm
(0.97 in.)
233mm
(9.19 in.)
79mm
(3.10 in.)
79mm
(3.10 in.)
282mm
(11.10 in.)
70mm
(2.75 in.)
74mm
(2.89 in.)
79mm
(3.11 in.)
77mm
(3.03 in.)
237mm
(9.34 in.)
Encore HD Encore HD+ and XD
(HD+ Stamped on Encore HD+)
Figure 8 Encore Pump dimensions

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Installation
Pump Tubing Installation
Standard 8-mm OD Poly Tubing
NOTE: Cut the poly tubing with a tubing cutter.
Powder cross-contamination may result if the
powder tubing is cut unevenly.
1. Install the poly tubing (3) into the lower Y block
(1) and push to internal connector fitting (not
shown)
Flexible 8-mm OD Tubing
NOTE: The barbed adapters used to connect
flexible tubing to the pump are shipped with the
pump.
1. Install the end of the adapter (2) into the lower
Y block (1). Push to internal connect fitting.
2. Push the flexible powder tubing (4) over the
barbed ending of the adapter (2).
Poly Tubing
Flexible Tubing
2
1
3
4
Figure 9 Powder Tubing Installations
1. Lower Y block
2. Barbed tubing adapter
3. Poly tubing
4. Flexible tubing
Pump to Cabinet or Panel
WARNING: Allow only qualified
personnel to perform the following tasks.
Follow the safety instructions in this
document and all other related
documentation.
Follow the below instructions to install the pump to
an existing pump panel.
1. See Figure 10. Make sure that the gaskets on
the pump (1), are not damaged, replace them if
necessary.
2. Line the pump to the appropriate manifold
positions (4) on the cabinet wall (3). See Pump
Port Functions on page 7 for port locations.
3. Secure the pump hand tight to the cabinet wall
with the pump mounting hardware (2).
4. Tighten all hardware securely.
1
2
3
4
Figure 10 Pump Mounting to Cabinet
1. Pump
2. Pump mounting hardware
3. Panel or cabinet wall
4. Manifold

EncorerHD Pump 11
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Maintenance
Perform these maintenance procedures to keep your pump operating at peak efficiency.
WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety
instructions in this document and all other related documentation.
NOTE: You may have to perform these procedures more or less frequently, depending on factors such as
operator experience and type of powder used.
Frequency Part Procedure
Daily Visual Inspection
Pinch Valves
Inspect the pinch valve body for
signs of powder leakage. If
powder is seen in the pinch valve
body or there are stress cracks in
the pinch valves, replace the pinch
valves and filter discs.
Every Six Months
or
Each Time You
Disassemble the Pump
Lower Y Block
Upper Y Block
NOTE: To reduce downtime, keep
a spare upper manifold and set of
lower wear blocks in stock to install
while the other set is being
cleaned.
Disassemble the pump and
inspect the lower Y block and
upper Y-block for signs of wear or
impact fusion. Clean these parts
in an ultrasonic cleaner if
necessary.
Gasket Inspect the gasket for damage.
Replace if necessary.

EncorerHD Pump
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Troubleshooting
WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety
instructions in this document and all other related documentation.
These troubleshooting procedures cover only the most common problems that you may encounter. If you
cannot solve the problem with the information given here, call the Nordson Finishing Customer Support
Center at [phone] or contact your local Nordson representative for help.
Problem Possible Cause Corrective Action
1. Reduced powder
output (pinch valves
are opening and
closing)
Blockage in the powder tubing to
the spray spray spray gun
Check the tubing for blockages.
Purge the pump and spray gun.
Defective pump air flow control
valve
Clean the pump air flow control valve.
If the problem persists, replace the
pump air flow control valve.
Defective pump check valve Replace the check valves.
2. Reduced powder
output (pinch valves
are not opening and
closing)
Defective pinch valve Replace the pinch valves and filter
discs.
Defective solenoid valve Replace the solenoid valve. Refer to
Solenoid and Flow Control Valve
Functions on page 7 to determine
which solenoid valve controls the
affected pinch valve.
Defective pump check valve Replace the check valves.
3. Reduced powder
input (loss of suction
from feed source)
Blockage in the powder tubing
from the feed source
Check the tubing for blockages.
Purge the pump and spray gun.
Loss of vacuum at the vacuum
generator
Check the vacuum generator for
contamination.
Check the pump panel exhaust
muffler. If the exhaust muffler
appears to be plugged, replace it.
Defective pump air flow control
valve
Clean the pump air flow control valve.
If the problem persists, replace the
pump air flow control valve.
4. Spray gun fan pattern
changes
Defective pattern air flow control
valve
Clean the pattern air flow control
valve.
If the problem persists, replace the
pattern air flow control valve.

EncorerHD Pump 13
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Problem Possible Cause Corrective Action
5. Powder inside spray
gun inlet adapter
Internal nozzle O-ring worn Replace the internal nozzle O-ring.
Powder delivery hose not
seated properly in tubing
adapter
Loosen the retaining nut to remove the
nozzle and retaining nut assembly.
Pull the tubing adapter from the end of the
flexible powder tube.
Loosen the lock knob and gently pull the
flexible powder tubing out of the spray gun
adapter. Clean the surfaces.
If the end of the feed tubing is damaged,
cut the damaged end off with a tube cutter.
Remove the set screw and inlet adapter
from the spray gun. Blow the adapter and
powder tube clean.
Install the inlet adapter. Feed the flexible
powder tubing through the inlet adapter.
Tighten the lock knob. Install the tubing
adapter on the tube then gently pull the
tube back until the adapter stops against
the flange.
Install the nozzle and retaining ring.
6. Air leaking around
end cap
Multiplier gasket worn Replace the multiplier gasket.
7. Powder tubing too
stiff
Spiral wrap too close to the
spray gun
Remove any spiral wrap that is within 24
in. of the spray gun handle.
8. “Fingers” in spray
pattern
Pattern air setting too low Increase the pattern air setpoint.
Nozzle plugged Remove the nozzle, disassemble, and
clean.
Input air pressure too low Increase the input air pressure.
Calibration constants
incorrect
Verify that the calibration constants on the
manifold match what is entered in the
manual spray gun controller.
9. Powder delivery
problems: Surging,
fading, intermittent
flow, low flow
Assist air compensation
incorrect
Increase or decrease the assist air
compensation setting for the current
preset.
Set the controller to a positive number if
the spray gun is surging.
Set the controller to a negative number if
the spray gun is fading.
Fluidizing air pressure
incorrect
Increase or decrease the fluidizing air
pressure. The powder should be gently
boiling.
Powder damp or
contaminated
Check the air driers and filter/separators.
Check the powder in the feed hoppers and
make sure it flows easily.
Continued...

EncorerHD Pump
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Problem Possible Cause Corrective Action
Powder delivery
problems: Surging,
fading, intermittent flow,
low flow (cont.)
Suction tubing too long Move the hoppers closer to the pump
and shorten the suction tube length.
The tube length must be less than
12 ft. from the powder feed.
Suction or delivery tubing blocked
or kinked
Check the tubing. Blow out the tubing
or replace it as necessary.
Pump panel regulator pressure
incorrect
Adjust the regulators in the pump
panel to the proper pressures. Refer
to page Delivery Check for the proper
pressure settings.
Pump adapter 8-mm tube fitting
loose
Tighten the 8-mm tube fitting.
Pump mount O-rings worn Replace the pump mount O-rings.
Refer to your pickup tube instruction
sheet or hopper manual for part
numbers.
Pickup tube not tightly threaded
into pump mount
Tighten the pickup tube into the
pump mount.
Air leaking around lock knob Replace the lock knob O-ring.
Pump inlet tube retaining nut or
O-ring loose
Check the O-ring and tighten the
retaining nut.
Check the barbed tubing adapter for
wear.
Check for air leaks between the
manifold and cabinet and between
the manifold and pump.
Improper delivery tubing
arrangement
The delivery tubing must be arranged
in a 3-ft. coil and be parallel to the
ground.
Delivery tubing length is not to
specification
The delivery tubing must be 60 ft.
from the pump to the spray gun.
Continued...

EncorerHD Pump 15
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Corrective ActionPossible CauseProblem
Powder delivery
problems: Surging,
fading, intermittent
flow, low flow (cont.)
Problem with pump or pump
control manifold
Vacuum check (requires 0−30 in. Hg
vacuum gauge)
1. Purge the pump and spray gun.
Do not load a new color.
2. Set the kV output to 0. Set the
powder flow to 35%.
3. Disconnect the powder tubing
from the pump. Connect a
vacuum gauge to the suction
fitting or remove the fitting nut and
place your finger over the fitting.
4. Trigger the spray gun and watch
the vacuum gauge or feel for the
vacuum.
SFor correct vacuum readings
(9−14 in. Hg) on both sides of
pump (or you feel less vacuum on
one side of pump than the other),
proceed to Delivery Check
procedure.
SFor low vacuum readings (less
than 8 in. Hg) on one side of
pump (or you feel less vacuum on
one side of pump than the other),
proceed to Suction Check
procedure.
SFor low vacuum readings (less
than 8 in. Hg) on both sides of
pump (or you feel weak or no
vacuum on both sides of pump
cycle), proceed to Suction Check
procedure.
10. Pump is bad, requires
repair
(Suction Check)
Fluidizing tube blinded or plugged Replace the fluidizing tubes.
Verify O-rings are in place. If
missing, powder buildup could occur
in the muffler.
NOTE: The filter discs must be
installed flush with the aluminum
body. If the discs are even slightly
raised, the gasket will leak, causing
the pump to malfunction.
Pinch valve leaking Replace the pinch valves and filter
disks.
Lower Y-block plugged Remove and clean the lower
Y-blocks.

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Corrective ActionPossible CauseProblem
11. Control manifold is
bad, requires repairs
(Suction Check)
Pump manifold valves 2 and 5 are
contaminated with powder
Remove and inspect the valves. If
they are contaminated, blow out the
manifold and replace the valves.
NOTE: If using an old harness with
three positions, use the supplied
adapter. If using a new harness with
two positions, the supplied adapter
can be discarded.
Vacuum generator is blocked Remove and inspect the vacuum
generator venturi nozzle. If it is
blocked, blow it out or replace the
vacuum generator.
1. Remove the vacuum generator at
the manifold. Check for vacuum
with your finger.
2. Remove the vacuum generator
vent hose at the bottom of the
cabinet (inside). Trigger the spray
gun on. Check for exhaust and
increase the powder flow.
3. Check for proper direction of the
check valve.
Delivery Check
The problem is not in the pump or the control
manifold. Check for problems in delivery tubing or
suction tubing.
1. Reconnect the delivery tubing to the pump.
2. Trigger the spray gun and observe the
vacuum gauge. The correct vacuum
reading ranges from 9−14 in. Hg.
If the problem is in the delivery tubing or
spray gun:
1. Clean or replace the delivery tubing.
2. Check the spray gun lock nut O-ring and
replace it if it is missing or damaged.
3. Remove the nozzle and powder tubing
adapter from the spray gun and clean or
replace it.
If the problem is in the suction tubing,
fittings, pickup tube, or powder:
1. Connect the suction tubing as shown in
Figure 11 on page 17.
2. Trigger the gun and observe the powder
flow.
Suction Check
Low vacuum reading: less than 8 in. Hg in one or
both sides of the pump
The problem is not in the pump or control manifold.
1. Remove the pump and replace it with a
functioning pump.
2. Connect the vacuum gauge to the pump
suction fitting.
3. Trigger the spray gun and observe the
vacuum gauge.
SIf the problem disappears, then check the
suction tubing fittings and adapter O-rings.
Clean the pickup tube. For
Color-on-Demandrsystems, proceed to
procedure on page 17.
SIf the problem persists, the suction tubing is
blocked. Replace the suction tubing.
SIf the problem disappears, the original pump
was bad. See Pump is bad, requires repair
in the Troubleshooting table.
SIf the problem remains, the pump control
manifold is bad. See Pump is bad, requires
repair in the Troubleshooting table.