Nordson Encore HD Referenzhandbuch

EncorerHD Pump Control Unit and

Power Supply

Customer Product Manual

Part 1606783-06

Issued 6/19

NORDSON CORPORATION •AMHERST, OHIO •USA

For parts and technical support, call the Industrial Coating

Systems Customer Support Center at (800) 433-9319 or

contact your local Nordson representative.

This document is subject to change without notice.

Check http://emanuals.nordson.com for the latest version

and available local languages.

Part 1606783−06 E2019 Nordson Corporation

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 2015. 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, iFlow, Nordson and the Nordson logo are registered trademarks

of Nordson Corporation.

All other trademarks are the property of their respective owners.

Table of Contents i

Part 1606783−06

E2019 Nordson Corporation

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.............................................

Introduction 2-1.............................................

Specifications 2-2...........................................

Pump Control Unit Certification Label 2-4....................

Encore HD Pump 2-5.......................................

HD Pump Components 2-6................................

Theory of Operation 2-8...................................

Pumping 2-8..........................................

Purging 2-10...........................................

Pump Control Manifold Components 2-12.....................

Installation 3-1.............................................

Wall/Rail Mount Systems 3-1.................................

Pump Control Unit Mount 3-1..............................

Interconnect Cable Connection 3-3.........................

System Connections 3-4.....................................

System Diagram 3-4......................................

Pump Control Unit Connections 3-6.........................

Spray Gun Connections 3-7...............................

Spray Gun Cable 3-7...................................

Air Tubing and Powder Tube 3-8.........................

Bundling Tubing and Cable 3-9..........................

Main System Air and Electrical Connections 3-10..............

Main System Air Supply 3-10.............................

Standalone, Rail Mount, and Wall Mount System Air Supply ........

3-11

Encore HD Powder Pump Hose 3-12.........................

Standard 8-mm OD Poly Tubing 3-12......................

Flexible 8-mm OD Tubing 3-12............................

Pump Adapter Installation 3-13..............................

Electrical Connections 3-14.................................

System Ground 3-14.........................................

Mobile Systems 3-14.......................................

Wall / Rail Mount Systems 3-14.............................

Table of Contents

Part 1606783−06 E2019 Nordson Corporation

Operation 4-1..............................................

European Union, ATEX, Special Conditions for Safe Use 4-1......

Maintenance 4-2............................................

Troubleshooting 5-1........................................

Pump Troubleshooting 5-2...................................

Pump Port Functions 5-3..................................

Manifold Troubleshooting 5-4.................................

Solenoid and Flow Control Valve Functions 5-5...............

Re-Zero Procedure 5-6......................................

Controller Interconnect Cable Test 5-6.........................

Repair 6-1.................................................

Removing Panel Assembly 6-2............................

Sub-Panel Components 6-3................................

Regulator Adjustment 6-3.................................

iFlow Module Repair 6-4...................................

Testing iFlow Modules 6-4...............................

Solenoid Valve Replacement 6-5.........................

Proportional Valve Cleaning 6-5..........................

Proportional Valve Replacement 6-5......................

Vibrator Motor Replacement 6-7............................

Fluidizing Tube Replacement 6-8...........................

Pump Disassembly 6-10....................................

Pump Assembly 6-12......................................

Pinch Valve Replacement 6-15..............................

Pinch Valve Removal 6-15................................

Pinch Valve Installation 6-16..............................

Parts 7-1...................................................

Introduction 7-1.............................................

Using the Illustrated Parts List 7-1..........................

Pump Control Unit 7-2.......................................

Panel Assembly 7-4......................................

iFlow Module 7-6.........................................

Manifold Assembly 7-7....................................

Pump 7-9................................................

Spare Parts 7-11........................................

Wall/Rail Mount System 7-12................................

Powder Hose and Air Tubing 7-12...........................

Miscellaneous Options 7-13.................................

Wiring Diagrams 8-1........................................

Change Record i

Part 1606783−06

E2019 Nordson Corporation

Change Record

Revision Date Change

01 10/15 New release

02 03/16 Updated gaskets.

04 1/18 Updated for new Encore HD pump information.

05 11/18 Replacing part number 1606690 with 1615026

06 6/19 Update part lists for pump control, panel assembly, manifold assembly,

pump, spare parts, powder hose and air tubing.

Change Record

Part 1606783−06 E2019 Nordson Corporation

Safety 1-1

Part 1606783−06

E2019 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 1606783−06 E2019 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 1606783−06

E2019 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 1606783−06 E2019 Nordson Corporation

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