Nordson Encore LT Automatic Customer Product Manual Download Page 1

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Encore

LT Automatic

Powder Spray Controllers

Customer Product Manual

Part 1604858-01

Issued 11/13

NORDSON CORPORATION

•

AMHERST, OHIO

•

USA

For parts and technical support, call the

Finishing Customer Support Center at (800) 433-9319.

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

This document is subject to change without notice.

Summary of Contents for Encore LT Automatic

Page 1: ...art 1604858 01 Issued 11 13 NORDSON CORPORATION AMHERST OHIO USA For parts and technical support call the Finishing Customer Support Center at 800 433 9319 Check http emanuals nordson com finishing fo...

Page 2: ...kson Street Amherst OH 44001 Notice This is a Nordson Corporation publication which is protected by copyright Original copyright date 2011 No part of this document may be photocopied reproduced or tra...

Page 3: ...Change Record i Part 1604858 01 E 2013 Nordson Corporation Change Record Revision Date Change 01 10 2013 Replaces 1107712...

Page 4: ...Change Record ii Part 1604858 01 E 2013 Nordson Corporation...

Page 5: ...on 1 3 Disposal 1 3 Description 2 1 Introduction 2 1 Controller Components 2 2 Triggering 2 3 Single Dual Gun Controller 2 3 Multi Gun Controller 2 3 Interlock Keyswitch 2 3 Specifications 2 4 Special...

Page 6: ...10 Power Up Sequence 3 10 Controller Automatic Manual Configuration 3 10 Entering Configuration Mode 3 11 Function Settings 3 11 Controller Triggering 3 12 Continuous 3 12 External 3 12 External Sign...

Page 7: ...s List 6 5 Dual Controller Parts 6 6 Dual Controller Parts 6 7 Dual and Multi Gun Rear Panel Sub Assembly 6 8 Dual and Multi Gun Rear Panel Sub Assembly Parts List 6 9 Multi Gun Controller Parts 6 10...

Page 8: ...Table of Contents vi Part 1604858 01 E 2013 Nordson Corporation...

Page 9: ...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...

Page 10: ...devices S 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...

Page 11: ...ed S 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...

Page 12: ...Safety 1 4 Part 1604858 01 E 2013 Nordson Corporation...

Page 13: ...wo gun controllers is available for the Dual Gun Controller The Multi Gun Controller can control from 4 to 8 automatic guns Optional Encore Axis Controllers can be installed in a multi gun controller...

Page 14: ...a I O board power distribution terminal blocks air distribution manifold and pressure gauge interlock keyswitch trigger all switch and power switch Dual Automatic Controller Multi Gun Controller 2 3 4...

Page 15: ...guns manually Interlock Keyswitch The Interlock keyswitch multi gun controller only has three positions Ready Normal operation Guns can be triggered as long as the conveyor is running This prevents po...

Page 16: ...s Location Rating for Controllers without Axis Controllers Zone 22 or Class II Division 2 S Dust Ingress Protection IP6X Special Conditions for Safe Use To meet ATEX requirements for the European Unio...

Page 17: ...98 23 5 1835 72 25 500 19 7 544 21 4 6 x 10 0 Mounting Holes 478 18 8 34 1 3 Dual Controller Multi Gun Controller 4X M5 THREAD TYP TOP BOTTOM Single Controller 75 2 953 200 7 87 75 2 963 63 2 46 40 1...

Page 18: ...0 60Hz Pn 100VA OUTPUT Vo peak 19V Io peak 1 0A WARNING POTENTIAL ELECTROSTATIC CHARGING HAZARD SEE INSTRUCTION MANUAL EN50177 FM11ATEX0057X 2 3 D Dual Gun Controller Label ENCORE LT Ex tc IIIC T60 C...

Page 19: ...275VA OUTPUT Vo peak 19V Io peak 1 0A WARNING POTENTIAL ELECTROSTATIC CHARGING HAZARD SEE INSTRUCTION MANUAL EN50177 FM11ATEX0057X 2 3 D Multi Gun 4 8 Guns Controller with Axis Controller Label ENCOR...

Page 20: ...Description 2 8 Part 1604858 01 E 2013 Nordson Corporation...

Page 21: ...ypad Keypad Line Filter Manifold 1 Rear Panel Front Panel Gun 2 Front Panel Gun 1 Flow Atomize Wash Wash Manifold 2 Flow Atomize Gun Cable Gun Cable Gun 1 Gun 2 Pump 2 Pump 1 24 VDC 24 VDC Powder Hose...

Page 22: ...r Power Distribution Panel Multi Gun Controller Line Filter Power Distribution I O Board Manifold 1 Trigger 1 Trigger 2 Rear Panel Front Panel Gun 2 Front Panel Gun 1 Flow Atomize Wash Wash Manifold 2...

Page 23: ...Install a controller on the bracket tray and line up the holes in the enclosure with the holes in the tray flanges 7 If installing only one controller secure it to the bracket flanges with four M5 x...

Page 24: ...Controller Mounting NOTE If the multi gun controller is equipped with Axis Controllers it must be located outside the spray zone Locating it inside the spray zone 3 feet or 1 meter on all sides of th...

Page 25: ...with single and dual controllers Refer to Parts for ordering information 4 L1 L2 GND 1 2 3 5 6 7 8 1 2 1 2 2 BROWN BLUE GRN YEL L1 L2 GND 3 BLUE 2 1 GRN YEL 4 5 6 7 8 Dual Controller Single Controller...

Page 26: ...4VDC WHITE ATOMIZING WHITE FLOW BLACK DC COM RED 24VDC 1 2 3 4 RED AIR WASH 5 BLACK AIR WASH 6 J4 6 5 3 4 1 2 J2 GUN POWER GREEN CHASSIS BLACK COM RED OUTPUT WHITE uA 4 3 2 1 J3 TRIGGER AUTO MAN JP1 T...

Page 27: ...Only with Axis Controller Figure 3 6 Multi Gun Controller Power Air and Gun Connections rear cover and rear kick panel removed 1 Air supply tubing 16mm blue 2 Gun cables 3 Gun air wash tubing 4mm clea...

Page 28: ...block on the trigger distribution board NOTE If the conveyor interlock is not used the keyswitch must be set to Bypass in order to operate the guns GND T8 COM T7 T6 T5 T4 T3 T2 T1 J6 J4 J3 J1 J2 J5 E...

Page 29: ...ng to the air wash connectors on the gun controller panels 2 Connect the gun cables to the receptacles on the gun controller panels Tighten the cable nuts securely 3 Route the air wash tubing and gun...

Page 30: ...ee Pump Powder Hose Figure 3 9 Pump Connections Controller Configuration Power Up Sequence When power is applied to the system the controller goes through the following sequence 1 All displays and LED...

Page 31: ...Atomizing Air Classic Total Flow Smart Flow Smart Coat Settings KV A Panel KV uA Selection Smart Flow Mode Indicator Flow Air Classic Powder Flow Rate Smart Flow Enable Disable Trigger LED Figure 3 10...

Page 32: ...m an external source such as a PLC or from the Trigger All switch on the front of the controller cabinet External Signals Trigger 10 mA typical 24V 5 maximum Conveyor 50 60 Hz 120V 10 at 10 mA RMS max...

Page 33: ...ff then on Input State Table State Trigger Conv Lockout KV Display Flow Display Atomizing Display Trigger LED System Status No Trigger Conveyor Off Locked Out Off Off Off Set Pt CO Set Pt LO Set Pt OF...

Page 34: ...System Setup 3 14 Part 1604858 01 E 2013 Nordson Corporation...

Page 35: ...tion Refer to Setup for configuration settings Low Power Mode Pressing and holding the Enable Disable button for three seconds puts the gun controller to sleep low power mode The displays and LEDs dim...

Page 36: ...the kV or A setpoint is displayed The flow and atomizing or total flow setpoints are always displayed Electrostatic Settings Electrostatic output can be set in Select Charge mode or in Custom or Class...

Page 37: ...ed the faster the units change S The valid AFC range is 5 100 A S The valid STD range is 0 or 25 100 kV Classic Electrostatic Mode Classic Mode is the optional electrostatic mode The controller must b...

Page 38: ...setpoint The longer a button is pressed the faster the units change The valid AFC range is 5 100 A Encore LT PE Mode To configure the controller for the Encore PE system set function number 3 Electro...

Page 39: ...sic Flow mode the Smart Flow LED is off NOTE Refer to page 3 11 for a list of the mode defaults and configuration instructions Flow Air or Flow Air Total Flow or Atomizing Air Figure 4 4 Flow Setting...

Page 40: ...y as required The data in this table was collected using 20 feet of 11mm ID powder tubing and a typical white epoxy powder For higher output use 12 7mm ID powder tubing Powder output values in g min a...

Page 41: ...ts through the booth The guns should be triggered automatically by your triggering device Alternately you can use the Trigger All switch if you have a multi gun controller Continuous Trigger Mode Star...

Page 42: ...trollers to sleep 3 Turn off the system air supply and relieve the system air pressure 4 If shutting for a long period of time turn off the controller power 5 Perform maintenance on the powder pumps a...

Page 43: ...Remove the parts to be cleaned Remove the O rings Blow off the parts with low pressure compressed air NOTE Do not allow O rings to come in contact with the cleaning solution 3 Place the parts in the...

Page 44: ...Operation 4 10 Part 1604858 01 E 2013 Nordson Corporation...

Page 45: ...nformation given here contact your local Nordson representative for help Controller Faults Problem Possible Cause Corrective Action 15 Trigger LED blinks gun does not spray Trigger signal received con...

Page 46: ...d inspect the nozzle deflector and electrode assembly Replace worn parts as necessary If excessive wear or impact fusion is a problem reduce the flow and atomizing air Damp powder Check the powder sup...

Page 47: ...r Powder hose too long or diameter too small 11mm ID hose length should be no longer than 7 62 m 25 ft Shorten hose if necessary If hose must be longer switch to 1 2 in ID hose Gun powder path plugged...

Page 48: ...e resistance as described in the gun manual If the electrode assembly is good remove the gun power supply and check its resistance as described in the gun manual Poorly grounded parts Check the convey...

Page 49: ...or disconnect ahead of the controller before opening the controller enclosures Failure to observe this warning could result in a severe electrical shock and personal injury CAUTION Electrostatic sensi...

Page 50: ...Part 1604858 01 E 2013 Nordson Corporation Single Controller Parts See Figures 6 1 and 6 2 and the parts list on the following page 1 4 2 3 5 7 8 6 9 10 11 12 13 15 14 Figure 6 1 Single Controller Par...

Page 51: ...d 1 5 982916 SCREW flat head socket M5 x 10 black 4 6 1108279 KIT PCA control Encore LT 1 7 982881 SCREW pan head recessed M4 x 6 zinc 4 8 983403 WASHER lock split M4 steel zinc 4 9 984702 NUT hex M5...

Page 52: ...tion Single Controller Rear Panel Parts This panel is used only on the single gun controller 20 16 17 17 18 19 21 24 22 23 25 26 26 27 28 29 30 31 28 29 30 31 28 29 30 31 32 33 34 35 36 40 39 38 Figur...

Page 53: ...in conduit 1 25 1107693 S GASKET rear panel Encore auto 1 26 982824 S SCREW pan head recessed M3 x 8 with lockwasher 4 27 1107695 S POWER SUPPLY 24VDC 60W 1 28 984702 S NUT hex M5 brass 3 29 983401 S...

Page 54: ...04858 01 E 2013 Nordson Corporation Dual Controller Parts See Figure 6 3 and the parts list on the following page 1 4 6 2 3 5 7 8 6 8 11 9 10 12 13 14 15 16 17 18 19 20 11 12 13 15 21 Figure 6 3 Dual...

Page 55: ...WASHER lock split M4 steel zinc AR 9 984715 NUT hex M4 steel zinc 2 10 1107696 FILTER line RFI power 3A w 0 25 Q D 1 11 984702 NUT hex M5 brass 2 12 983401 WASHER lock split M5 steel zinc 2 13 983021...

Page 56: ...on Dual and Multi Gun Rear Panel Sub Assembly This panel is used on both the dual controller and the multi gun controller 1 2 5 3 4 9 6 7 8 15 21 20 10 11 12 13 14 16 15 17 18 19 Figure 6 4 Rear Panel...

Page 57: ...1 983021 WASHER flat 0 203 x 0 406 x 0 040 brass 2 12 302189 WIRE ground assembly 10 5 in 1 13 240674 TAG ground 2 14 1108313 MUFFLER exhaust R1 8 1 15 1030873 VALVE check M8 tube x R1 8 M input 2 16...

Page 58: ...Parts 6 10 Part 1604858 01 E 2013 Nordson Corporation Multi Gun Controller Parts Front Panel Parts 1 4 2 3 5 7 8 6 10 8 11 15 15 16 9 12 13 14 Figure 6 5 Multi Gun Controller Front Panel Parts...

Page 59: ...ctrlr packaged AR 5 982916 SCREW flat head socket M5 x 10 black AR 6 1108279 KIT PCA control Encore LT AR 7 982881 SCREW pan head recessed M4 x 6 zinc AR 8 983403 WASHER lock split M4 steel zinc AR 9...

Page 60: ...Panel Parts See Figure 6 4 for the dual and multi gun rear panel sub assembly and parts list Each panel provides the outputs for 2 automatic spray guns 2 1 3 4 5 7 8 6 9 10 20 12 11 13 14 15 16 17 18...

Page 61: ...ING 3 8 RPT 4 10 mm tube 2 14 972091 CONNECTOR male elbow 6 mm tube x 3 8 in unithread 1 15 972143 CONNECTOR male elbow 16 mm tube x 1 2 in unithread 1 16 900742 TUBING polyurethane 6 4 mm blue AR 17...

Page 62: ...ve air tubing 900741 Air tubing 6 mm black 900618 Air tubing 8 mm blue 900619 Air tubing 8 mm black 900740 Air tubing 10 mm blue 900517 Tubing poly spiral cut 0 62 in ID 301841 Strap Velcro w buckle 2...

Page 63: ...Wiring Diagrams 7 1 Part 1604858 01 E 2013 Nordson Corporation Section 7 Wiring Diagrams...

Page 64: ...Wiring Diagrams 7 2 Part 1604858 01 E 2013 Nordson Corporation...

Page 65: ...D ENCORE AUTO CONTROLLER MANIFOLD ASSY A C POWER HARNESS 1500mm CONNECTOR WIRES 1065542 N SK1 RED 24VDC BLACK DC COM SK2 1 60W DC POWER SUPPLY 1107695 2 3 4 5 6 L GREEN YELLOW BLUE BROWN LT BLUE BROWN...

Page 66: ...ACK NOZZLE 6 J4 FLOW NOZZLE ATOMIZING 6 5 3 4 1 2 J2 GUN ENCORE LT AUTO KEYPAD PANEL ENCORE AUTO CONTROLLER MANIFOLD ASSY 1500mm CONNECTOR WIRES 1065542 CONTROLLER POWER JUMPER HARNESS POWER CHASSIS 7...

Page 67: ...BLUE CON 1 CON 2 CON 3 CON 4 CON 5 BLACK COM BLACK COM BLACK COM BLACK COM COM WHITE B WHITE C WHITE D WHITE E WHITE F WHITE G WHITE H BLUE BLUE BLUE TRIGGER DISTRIBUTION HARNESS SWITCHED POWER L1 L2...

Page 68: ...C BLACK DC COM SK2 1 60W DC POWER SUPPLY 1107695 2 3 4 5 6 L GREEN YELLOW BLUE BROWN GND REAR PANEL CABINET GND GREEN YELLOW TO GUN 2 CONTROL PCA J1 SEE SHEET 3 CONTROLLER POWER JUMPER HARNESS POWER A...

Page 69: ...5 3 4 1 2 J2 GUN ENCORE LT AUTO KEYPAD PANEL CONTROLLER POWER JUMPER HARNESS POWER COM OUTPUT 2 BLACK 3 RED uA 4 WHITE 7 GREEN CHASSIS GREEN CHASSIS TRIGGER DISTRIBUTION HARNESS WHITE TRIGGER A A TO T...

Page 70: ...4 9 EC ATEX Directive Standards Used for Compliance EN ISO12100 1 2010 EN60204 1 2006 EN61000 6 3 2007 FM7260 1996 EN60079 0 2009 EN50050 2006 EN61000 6 2 2005 EN60079 31 2009 EN50177 2009 EN55011 200...

Page 71: ...AUTO ENCORE 1099824 GUN TUBE MT AUTO ENCORE 5FT 1097500 GUN TUBE MT AUTO ENCORE 6FT OPTIONS 1604084 EXTENSION SPRAY 90 DEGREE ENCORE CABLES 1097537 CABLE AUTO ENCORE 8M 1097539 CABLE AUTO ENCORE 12M 1...

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