Nordson Encore LT Product Manual Download

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Table of Contents

Part 1604857-04

2014 Nordson Corporation

System Setup

3-1

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

Controller Rail Mounting

3-1

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

Controller Wall Mounting

3-2

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

System Connections

3-3

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

System Diagram

3-3

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

Controller Connections

3-4

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

VBF System Setup

3-5

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

Feed Hopper and Wall/Rail Mount System Setup

3-8

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

Adapter Kit or Coupling Installation

−

Wall/Rail Mount Systems . . . . . . .

3-10

Coupling Installation

3-10

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

Adapter Installation

3-10

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

Spray Gun Connections

3-11

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

Gun Cable

3-11

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

Air Tubing and Powder Hose

3-12

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

Bundling Tubing and Cable

3-13

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

System Air Connections

3-13

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

System Air Supply

3-13

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

Mobile Systems

3-13

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

Wall/Rail Mount Systems

3-13

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

System Electrical Connections

3-15

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

Power Supply

3-15

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

System Ground

3-15

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

Controller Configuration

3-16

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

Power Up Sequence

3-16

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

Entering Configuration Mode

3-16

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

Function Settings

3-17

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

Vibratory Box Feeder Settings

3-17

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

Continuous Operation

3-17

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

Shut Off Delay

3-17

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

Exiting Configuration Mode

3-17

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

Summary of Contents for Encore LT

Page 1: ...t 1604857 04 Issued 06 14 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 ...

Page 2: ...44001 Notice This is a Nordson Corporation publication which is protected by copyright Original copyright date 2013 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 regis...

Page 3: ...n Date Change 01 10 2013 Original publication date 02 01 2014 New flat spray electrode holder and assembly new conical nozzle kit and conical electrode assembly 03 05 14 Page 7 3 new trigger axle P N 1605713 Page 7 5 new nozzle P N s 04 06 14 New flat and conical electrode holders ...

Page 4: ...Change Record ii Part 1604857 04 E 2014 Nordson Corporation ...

Page 5: ...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 Mobile System Components 2 2 Rail Mount System Components 2 2 Wall Mount System Components 2 2 Specifications 2 3 Mobile System with VBF 2 3 Mobile System with 50Lb Feed Hopper 2 3 Equipment Labels 2 4 Powder Spray Gun Certification Labels 2 4 Controller Certification Label 2 4 ...

Page 6: ...pling Installation 3 10 Adapter Installation 3 10 Spray Gun Connections 3 11 Gun Cable 3 11 Air Tubing and Powder Hose 3 12 Bundling Tubing and Cable 3 13 System Air Connections 3 13 System Air Supply 3 13 Mobile Systems 3 13 Wall Rail Mount Systems 3 13 System Electrical Connections 3 15 Power Supply 3 15 System Ground 3 15 Controller Configuration 3 16 Power Up Sequence 3 16 Entering Configurati...

Page 7: ...w Mode Settings 4 5 Classic Flow Mode Settings 4 6 Spray Gun Operation 4 7 Electrode Air Wash Operation 4 7 Daily Operation 4 7 Startup 4 7 Purging 4 8 Powder Box Installation 4 8 Vibratory Box Feeder Operation 4 9 Changing Flat Spray Nozzles 4 10 Changing Conical Nozzles and Deflectors 4 11 Installing the Optional Pattern Adjuster Kit 4 12 Shutdown 4 12 Maintenance 4 13 Recommended Cleaning Proce...

Page 8: ... List 7 3 Spray Gun Options 7 4 Miscellaneous Spray Gun Options 7 4 Flat Spray Nozzles 7 5 Cross Cut Nozzles 7 5 45 Degree Corner Spray Nozzle 7 6 45 Degree In Line Flat Spray Nozzle 7 6 Conical Nozzle Deflectors and Electrode Assembly Parts 7 7 Conical Nozzle and Deflectors 7 7 Conical Nozzle Kit 7 7 Conical Electrode Assembly 7 7 Pattern Adjuster Kit 7 8 Lance Extensions 7 8 Pattern Adjuster Kit...

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 may result in injury to persons or damage to property Some examples of unintended use of equipment include S using incompatible materials S making unauthorized modifications S removing or bypassing s...

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 that cannot be enclosed or otherwise guarded for practical reasons Fire Safety To avoid a fire or explosion follow these instructions S Do not smoke weld grind or use open flames where flammable mat...

Page 11: ...ded 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 must wear shoes with conductive soles or use a ground strap to maintain a connection to ground when working with or around electrostatic equipment S Operators must maintain skin to handle contact bet...

Page 12: ...Safety 1 4 Part 1604857 04 E 2014 Nordson Corporation ...

Page 13: ...Mobile system with vibratory box feeder S Mobile system with feed hopper S Rail mount system S Wall mount system Mobile System with Hopper Mobile System with Vibratory Box Feeder Figure 2 1 Encore LT Mobile Manual Powder Systems NOTE The Encore LT Manual Powder Spray System is also available as a transportable demonstration system which includes the components listed in Section 7 Parts ...

Page 14: ...lude S Encore LT manual controller S Encore LT manual spray gun S Encore Generation II powder feed pump S Pump adapter kit and coupling for use on HR NHR feed hoppers S Rail mount bracket kit S Grounding kit S 11 mm powder hose air tubing spiral wrap Velcro straps S Air filter kit NOTE Powder can be also be supplied from an Encore in line pump mounted in a feed center Wall Mount System Components ...

Page 15: ...ndensing S Ambient Temperature Rating 15 to 40 _C 59 104 _F S Hazardous Location Rating for Applicator Zone 21 EU or Class II Division 1 Group F and G S Hazardous Location Rating for Controller Zone 22 EU or Class II Division 2 Group F and G S Dust Ingress Protection IP6X S Vibrator Table Capacity 25 kg 50 lb box of powder Mobile System with VBF Height 995 mm 35 2 in Length 820 mm 32 25 in Wheel B...

Page 16: ...un Certification Labels Controller Certification Label EN 50050 FM11ATEX0057X ENCORE LT Ex tc IIIC T60 C Dc 2 3 D T 15 to 40 C A NORDSON CORP AMHERST OH USA Vn 100 250Vac 7n 50 60Hz Pn 100VA OUTPUT V peak 19V Io peak 1 0A WARNING POTENTIAL ELECTROSTATIC CHARGING HAZARD SEE INSTRUCTION MANUAL ...

Page 17: ... 2 and one 10 dished lock washer 9 2 Install the controller bracket 1 on the rail bracket 5 with two M8 split lock washers 7 and two M8 x 70 hex head cap screws 8 3 Thread the two M8 jam nuts 4 onto the two M8 x 40 screws 3 then thread the two screws into the holes in the rail bracket 1 2 4 5 6 8 7 3 2 10 9 9 Figure 3 1 Rail Mount Kit and Parts Tray Installation 1 Controller bracket 2 M5 x 12 scre...

Page 18: ...ing kit instructions Controller Wall Mounting See Figure 3 2 Wall mount systems are shipped with a bracket kit that includes the wall mount bracket and the fasteners required to secure the controller to the bracket The bracket allows the controller to be installed perpendicular to the wall or at an angle in 30 degree increments 1 Install the bracket on the wall with 3 8 in fasteners not included 2...

Page 19: ...g bracket are shipped in a kit for mounting at the customer s plant Purge Air Power Supply AC Power Cord Fluidizing Air Manifold 24VDC Air Wash Air Atomizing Air Flow Rate Air Gun cable 6mm black 4mm clear 8mm blue 8mm black 6mm blue Spray Gun Powder hose 6mm blue Pickup Tube VIibrator Motor Pump Input Air 10mm Filter VBF Power Cord 6mm black Conductive Encore LT Controller Main Control Board Keyp...

Page 20: ...BLUE GRN YEL 1 2 3 5 6 7 8 9 10 11 Figure 3 4 Encore LT Gun Controller Connections 1 Electrostatic ground to cart or booth 2 Vibrator motor power cord 3 Power cord 15ft 4 Atomizing air blue 8mm to pump 5 Air supply blue 10mm 6 Flow rate air black 8mm to pump 7 Gun cable to gun 8 Purge air black 6mm to gun 9 Fluidizing air blue 6mm to pickup tube or hopper 10 Fluidizing air needle valve 11 Air wash...

Page 21: ...See Figure 3 5 Install the pickup arm as shown using four M5 x 10 screws with integral washers 3 1 2 3 Figure 3 5 Pickup Arm Installation 1 Arm 2 Arm bracket 3 M5 x 10 screws x 4 3 See Figure 3 6 Install the collar 1 on the pickup tube 2 as shown Tighten the socket head screw to secure the collar 1 2 3 4 Figure 3 6 Collar Installation on Pickup Tube 1 Collar 2 M5 socket head screw black 3 Pickup t...

Page 22: ...e air tubing 6 S 6 mm blue fluidizing air tubing 9 8 See Figure 3 8 Route the tubing 4 6 9 through the grommet in the front panel of the cart tower as shown 9 Connect the tubing and powder hose as shown S 8 mm blue atomizing air tubing 4 to the pump top fitting S 8 mm black flow rate air tubing 6 to the pump bottom fitting S 6 mm blue fluidizing air tubing 9 to the bulkhead union 1 S 6 mm black fl...

Page 23: ...g tubing 12 Grommet Note Create service loop as noted before securing tubing to arm with straps WARNING The black fluidizing air tubing 2 the pickup tube connector and the bulkhead union 1 are conductive and provide a ground path to the cart Do not replace these components with non conductive components Refer to Parts for replacement tubing NOTE The pump is equipped with quick connect couplings th...

Page 24: ... pump 7 into the pump mount 5 with a slight twisting motion Connect the fluidizing and atomizing air tubing to the pump as shown NOTE Rail mount systems are shipped with a pump adapter kit and a coupling for use with pickup tubes designed for other pumps Refer to the installation instructions on page 3 10 8 Connect the 10 mm x 6 mm reducer 11 to the 10 mm elbow fitting on the hopper fluidizing pan...

Page 25: ...Figure 3 9 Encore LT Mobile System with Hopper Hopper and Pump Installation 1 Vent hose 2 Powder hose 3 Hose clamp 4 Blue atomizing air tubing 5 Pump mount 6 Black flow rate air tubing 7 Pump 8 Vent hose clamp 9 Blue fluidizing air tubing 10 Ground wire 11 10 x 6 mm reducer fitting 12 Grommet ...

Page 26: ...ting motion 2 Install the Encore pump into the coupling with a slight twisting motion Adapter Installation The adapter kit replaces existing pump adapters with external O rings on all threaded 0 360 in ID pickup tubes 1 Pull the pump adapter and pickup tube out of the pump mount on the hopper lid 2 Unscrew the pickup tube from the existing adapter 3 Screw the pickup tube into the Encore pump adapt...

Page 27: ... Gun Cable See Figure 3 11 1 Connect the gun cable to the GUN receptacle on the rear panel of the controller The cable plug and receptacle are keyed 2 Thread the cable nut onto the receptacle and tighten the nut securely 3 Secure the cable strain relief to the rear panel with one of the existing panel screws Mobile System Rail Wall Mount System Strain Relief Figure 3 11 Gun Cable Connection and St...

Page 28: ...6 meters 20 ft of 11 mm ID powder hose is shipped with the system If you must use a longer hose switch to 1 2 inch ID powder hose Refer to Parts for hose part numbers 4 Route the air tubing to the rear panel of the gun controller 5 See Figure 3 4 Connect the 6 mm black tubing to the purge air quick disconnect fitting 8 6 See Figure 3 13 Connect the 4 mm clear tubing and the flow control valve supp...

Page 29: ... air tubing 15 ft for dolly systems 25 ft for wall rail mount systems is available Refer to the Parts section for filter kits replacement elements and input air kit part numbers and ordering information Mobile Systems Connect 10 mm air tubing from your compressed air supply to the air input fitting on the rear panel of the dolly Wall Rail Mount Systems See Figure 3 14 1 Use the mounting bracket 4 ...

Page 30: ...ation 1 1 2 2 3 4 6 5 7 FROM SUPPLY TO CONTROLLER Figure 3 14 Air Filter Installation Wall and Rail Mount Systems 1 10 mm air tubing blue 2 10 mm tube x 1 2 male connectors 3 M5 screws 4 Bracket 5 Flow indicator 6 Release latch 7 Customer supplied fasteners ...

Page 31: ...stem must match the vibrator motor rating Wire the system power cord to a customer supplied three prong plug Connect the plug to a receptacle that supplies the correct voltage Wire Color Function Blue N neutral Brown L hot Green Yellow GND ground System Ground Mobile Systems See Figure 3 15 Connect the ground cable attached to the controller ground stud to a true earth ground Figure 3 15 System Gr...

Page 32: ...t rate Release the trigger and repeat the sleep wake up cycle Entering Configuration Mode To enter configuration mode press and hold the Plus and Minus buttons on the kV uA panel while either turning on power or pressing the Enable Disable button if the controller is already powered up After 1 second all panels flash CF for 3 seconds After 3 seconds the kV A panel displays F 1 for function 1 The c...

Page 33: ...d Powder Flow Control modes Vibratory Box Feeder Settings Continuous Operation To set the vibrator motor to continuous operation choose the on setting In this mode the vibrator motor turns on when the gun is first triggered and stays on until you press the Enable Disable button or turn off system power Shut Off Delay If you set a delay time the vibrator motor turns on when the gun is triggered and...

Page 34: ...System Setup 3 18 Part 1604857 04 E 2014 Nordson Corporation ...

Page 35: ...erature range of 15_C to 40_C with the Encore LT Powder Electrostatic Manual Applicators 2 The Encore LT Manual Controller can be installed in a non hazardous area or in a hazardous area defined as a Zone 22 3 Caution should be taken when cleaning plastic surfaces on the controller There is a potential for static electricity build up on these components Controller Interface See Figure 4 1 Use the ...

Page 36: ...Smart Flow LED is lit The air flow displays always show the setpoints Electrostatic Settings Electrostatic output can set in Select Charge mode Custom mode or Classic mode Custom or Classic mode is chosen when the controller is configured Set the electrostatic output depending on the shape and type of product being coated and the type of powder used Select Charger Mode The Select Charge modes are ...

Page 37: ...n is pressed 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 be configured to use this mode refer to page 3 16 for configuration instructions In Classic mode you can choose to control kV STD output or A AFC output but not both at the same time Classic ...

Page 38: ...the units change The valid AFC range is 5 100 A Encore Nano Feedback Control Mode NFC To configure the controller for the Encore NFC system set function number 3 Electrostatic Control to setting 2 Encore NFC When the controller function number 3 is set to NFC the electrostatic settings will allow the user to control both KV and A custom mode and they will be able to control the A setting to values...

Page 39: ...oller is configured for Classic Flow mode the Smart Flow LED is off NOTE Refer to page 3 16 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 Panels Smart Flow Mode Settings sets the powder flow rate Flow Air sets the powder velocity Total Flow Setting values for both are 0 99 of maximum output Press the and butt...

Page 40: ...ery velocity 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 are typical your results may vary Total Air Setting 20 40 60 80 100 Flow Output Setting B Powder Output in g min 20 45 26 20 27 45 40 79 128 105 138 100 60 118 176 215 220 235 80 168 240 288...

Page 41: ...ger Figure 4 5 Gun Controls Electrode Air Wash Operation Electrode air wash air continually washes the spray gun electrode to prevent powder from collecting on it Electrode air wash air is turned on and off automatically when the spray gun is triggered on and off Daily Operation Startup 1 Turn on the spray booth exhaust fan 2 Turn on the system air supply and power 3 Install a box of powder or a h...

Page 42: ...kV or A output when the gun is spraying and setpoints when the gun is off The air flow displays always show the setpoints On Initial Startup With the gun triggered air set to zero and no parts in front of the gun record the A output for each gun in the system Monitor the A output daily under the same conditions A significant increase in A output indicates a probable short in the gun resistor A sig...

Page 43: ...re the bag with a tie wrap Vibratory Box Feeder Operation When the controller is configured for a vibratory feed system the vibratory box feeder relay control is enabled The relay turns on the vibrator motor when the spray gun is triggered When the spray gun is triggered off the vibrator motor remains on for a configurable delay This delay prevents rapid on off motor cycling every time you trigger...

Page 44: ...s the Enable Disable button to put the controller to sleep in order to prevent accidental gun triggering 2 See Figure 4 7 Unscrew the nozzle nut counterclockwise 3 Pull the flat spray nozzle off the electrode assembly NOTE Re install the electrode assembly if it comes out of the powder outlet tube 4 Install a new nozzle on the electrode assembly The nozzle is keyed to the electrode assembly Do not...

Page 45: ...g 2 See Figure 4 8 Gently pull the deflector off the electrode assembly If only changing the deflector install the new one on the electrode assembly being careful not to bend the electrode wire 3 To change the entire nozzle unscrew the nozzle nut counterclockwise 4 Pull the conical nozzle off the electrode assembly NOTE Re install the electrode assembly if it comes out of the powder outlet tube 5 ...

Page 46: ...ctrode assembly and screw the nozzle nut clockwise until finger tight 4 Install a 16 19 or 26 mm deflector onto the electrode holder NOTE To clean the pattern adjuster use the Recommended Cleaning Procedure for Powder Contact Parts on page 4 13 Deflector Electrode Assembly Pattern Adjuster Kit Electrode Holder Figure 4 9 Pattern Adjuster Kit Installation Shutdown 1 Purge the spray gun by pressing ...

Page 47: ...arts NOTE Do not immerse the electrode assembly in solvent It cannot be disassembled cleaning solution and rinse water will remain inside the assembly 1 Fill an ultrasonic cleaner with BetaSolv or an equivalent emulsion cleaning solution at room temperature Do not heat the cleaning solution 2 Remove the parts to be cleaned from the gun Remove the O rings Blow off the parts with low pressure compre...

Page 48: ...e from the pump end 5 Remove the nozzle and electrode assembly and clean them with low pressure compressed air and clean cloths If impact fusion is present on the nozzle parts clean them using the Recommended Cleaning Procedure for Powder Contact Parts on page 4 13 Check the parts for wear and replace if necessary 6 Blow off the gun and wipe it down with a clean cloth Vibratory Box Feeder Pickup T...

Page 49: ...ubleshooting procedures cover only the most common problems If you cannot solve a problem with the information given here contact your contact Nordson technical support at 800 433 9319 or your local Nordson representative for help Controller Faults Problem Possible Cause Corrective Action 1 Trigger LED blinks gun does not spray Gun was triggered on when the controller was powered up or woken up Re...

Page 50: ...ectrode assembly worn affecting pattern Remove and clean 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 supply air filters and dryer Replace the powder supply if contaminated Low atomizing or flow air pressure Increase the atomizing and or flow air flow Improp...

Page 51: ...ply shorted Perform the Power Supply Resistance Test on page 5 6 5 No kV output from the spray gun mA 0 powder is spraying Spray gun power supply open Perform the Power Supply Resistance Test on page 5 6 Damaged gun cable Perform the Gun Cable Continuity Test on page 5 7 If an open or short is found replace the cable 6 No kV output and no powder output Malfunctioning trigger switch or cable Check ...

Page 52: ...e and check the manifold passages If the manifold is clean replace the valve Air tubing kinked or plugged Check the flow and atomizing air tubing for kinks Pump throat worn Replace the pump throat Pump not assembled correctly Check the pump Pick up tube blocked Check for debris or bag VBF units blocking pick up tube Vibratory box feeder disabled VBF units only Make sure sure the controller is conf...

Page 53: ...to a non zero value 13 No powder flow when gun is triggered On kV OK Flow Air or Total Flow set to zero Change settings to a non zero number Input air turned OFF Make sure air is being supplied to the controller 14 More than one key on the keypad quits working when pressed Flex connection from the keypad to the main board is not seated properly Loosen and re seat the flex circuit on the main board...

Page 54: ...meter probes If the resistance falls outside this range replace the power supply J2 3 YELLOW FEEDBACK J2 2 BLACK COMMON J2 1 RED OSC 280 320 Megohms at 500 VDC Figure 5 10 Power Supply Resistance Test Electrode Assembly Resistance Test Use a megohm meter to measure the resistance of the electrode assembly from the contact ring on the back to the antenna wire in the front The resistance should be 1...

Page 55: ... J1 5 J1 6 FEEDBACK GND BRAIDED SHIELD GRN WHT CABLE GND GRN BLK RED J2 2 J2 1 RED BLK ORG BLU WHT J3 1 J3 5 YEL J3 2 PURGE ORG J2 3 FEEDBACK YEL BLU J1 1 ORANGE J1 3 RED J1 6 GREEN J1 5 YELLOW J1 4 WHITE J1 FACE VIEW J1 2 BLACK AND BLUE J1 CONTROLLER END FACE VIEW J3 J3 FACE VIEW J3 1 J3 2 J3 3 J2 FACE VIEW POWER SUPPLY CONNECTOR J2 3 YELLOW J2 1 RED J2 2 BLACK J2 TO POWER SUPPLY TO GUN GROUND ST...

Page 56: ...Troubleshooting 5 8 Part 1604857 04 E 2014 Nordson Corporation ...

Page 57: ... Powder Path Replacement Gun Disassembly 1 See Figure 6 1 Remove the nozzle nut nozzle and electrode assembly 1 2 3 2 Remove the screws 11 12 and hook cover and housing 8 9 10 3 Pull the power supply harness out of the bulkhead then insert a small flat bladed screwdriver into the recess in the harness connector to release the catch Disconnect the gun cable from the power supply harness 1 2 3 12 11...

Page 58: ...ve it connected unless it must be replaced 22 Figure 6 2 Removing the Gun Body from the Handle Power Supply Replacement NOTE If replacing the powder path skip this procedure 1 Slide the power supply 5 out of the gun body 2 Check the gasket 6 on the back of the bulkhead 7 Replace it if it is damaged The gasket is stuck to the bulkhead with pressure sensitive adhesive 5 6 7 Figure 6 3 Removing the P...

Page 59: ...ll the base away from the handle swing the bottom of the ground pad 15 up and away from the handle then remove it Leave the ground wire connected to the ground pad 3 Push the inlet tube 25 up and out of the base then move the base out of the way and pull the inlet tube out of the handle 4 Push the outlet tube 4 out of the front of the gun body 13 5 Blow off the inlet tube outlet tube and elbow and...

Page 60: ...ith the handle and slide them together engaging the internal ribs of the gun body with the handle tabs NOTE Make sure that the power supply harness is not pinched between the bulkhead and the power supply Internal Ribs Handle Tabs Elbow Figure 6 5 Installing the Gun Body on the Handle 2 Insert your finger into the outlet tube at the front of the gun and align the inside end of the tube with the el...

Page 61: ...8 screw lock washer 16 17 and ground terminal from the ground pad 7 Remove the E ring 30 from the cable 8 See Figure 6 6 View C Pull the cable connectors out of the handle Disconnect the power supply harness from the gun cable by inserting a small flat bladed screw driver in the slot of the power supply harness connector to release the catch 9 Carefully disconnect the round trigger connector from ...

Page 62: ... up against the handle and ground pad and tighten securely the two M3 x 20 screws 12 in the base 7 See Figure 6 1 Install the bottom M3 x 20 screw 12 in the housing 9 and tighten it securely Trigger Switch Replacement Switch Removal 1 See Figure 6 6 Remove the ground pad as described in Cable Removal steps 1 5 You do not have to disconnect the ground cable from the ground pad 2 Pull out the round ...

Page 63: ...feed the bottom of the switch through the slot in the trigger recess and remove it from the handle Switch Installation NOTE A new axle 23A is included with a replacement trigger switch 1 See Figure 6 9 Orient the new switch with the grid facing away from the inlet tube then carefully feed the square bottom end of the switch 23 around the left side of the inlet tube 25 and through the slot in the t...

Page 64: ... recess Run your finger up and down on the switch to ensure it is securely adhered to the handle Figure 6 11 Installing the Trigger Switch Step 4 7 See Figure 6 7 Install the purge trigger 19 into the spray trigger 20 with the gusset oriented upward as shown Do not install the purge trigger upside down 8 Position the triggers in the handle and hold them in place while pressing the axle 23A through...

Page 65: ...warning could result in a severe electrical shock and personal injury CAUTION Electrostatic sensitive device To avoid damaging the controller circuit boards wear a grounding wrist strap and use proper grounding techniques when making repairs Front Panel Components Refer to Section 5 Troubleshooting for the controller electrical schematic and harness connections Refer to Section 7 Parts for repair ...

Page 66: ...nnections NOTE If replacing the relay board 2 JP1 must be jumped for a 115V vibrator motor For a 230V vibrator motor remove the jumper 3 2 4 1 5 6 7 8 9 2 J1 C2 C1 RL1 F1 F2 M1 M2 M3 JP1 1 2 L2 F L2 L1 F L1 Install jumper for 115V motor remove for 230V motor Figure 6 13 Sub Panel Parts Replacement 1 Manifold assembly 2 Relay board 3 Power supply 4 Line filter 5 Fluidizing air solenoid valve 6 Purg...

Page 67: ... of the enclosure 3 Disconnect the vibrator motor cable from the relay board then loosen the cord grip and pull the cable out of the panel 4 Route the new motor cable through the cord grip then connect the cable leads to the relay board as shown below Make sure the relay board jumper is set for the correct voltage ENCORE LT RELAY PCA J1 C2 C1 RL1 F1 F2 M1 M2 M3 JP1 1 2 L2 F L2 L1 F L1 Jumper JP1 f...

Page 68: ...Repair 6 12 Part 1604857 04 E 2014 Nordson Corporation ...

Page 69: ...er Feed Pump 1095927 Encore 150 and 300 mm Lance Extensions 1093657 Pattern Adjuster Kit for Lance Extensions 1100013 Pattern Adjuster Kit for Encore Manual Spray Guns 10984490 These manuals can be downloaded from http emanuals nordson com finishing click on Powder US then Encore Systems System Part Numbers Use these part numbers to order complete systems Part Description Note 1107897 SYSTEM dolly...

Page 70: ...oration Spray Gun Parts Illustration 1 2 4 5 6 7 8 9 10 11 12 13 14 23A 19 20 21 22 16 15 23 26 25 29 12 28 27 24 30 17 4A 4B 25B 25A 33 32 32A 35 35A 18 26A 26B 3 34 31 3A 3B Figure 7 1 Exploded View of Encore LT Manual Spray Gun and Accessories ...

Page 71: ...y assembly handgun Encore 1 14 1088558 S FILTER ASSEMBLY handgun 1 15 1106871 S HANDLE ground pad handgun Encore LT XT 1 16 983520 S WASHER lock internal M3 zinc 1 17 982427 S MACHINE SCREW pan head recessed M3 x 6 zinc 1 18 1096695 S ELBOW powder tube handgun 1 D 19 1081540 S TRIGGER setting handgun 1 20 1106873 S TRIGGER main handgun Encore LT XT 1 21 1106892 S ACTUATOR switch trigger Encore LT ...

Page 72: ...increments of one foot or one meter D Also available in wear resistant material Refer to Spray Gun Options E Optional 6 meter extension available refer to Spray Gun Options F For flat spray nozzle use only Use kit item 31 to convert for conical nozzle and deflector use AR As Required NS Not Shown Spray Gun Options Miscellaneous Spray Gun Options See Figure 7 1 Item Part Description Quantity Note 4...

Page 73: ...ith the spray gun All other flat spray nozzles are optional 1605845 2 5 mm Flat Spray 1605846 3 mm Flat Spray 1605847 4 mm Flat Spray 1605848 6 mm Flat Spray Figure 7 2 Flat Spray Nozzles Cross Cut Nozzles 1605849 60 Degree Cross cut 1605850 90 Degree Cross cut 1605851 2 5 mm Castle Figure 7 3 Cross cut Nozzles ...

Page 74: ...scription Note 1102872 NOZZLE corner spray Encore Figure 7 4 45 Degree Corner Spray Nozzle 45 Degree In Line Flat Spray Nozzle See Figure 7 5 Spray Pattern Narrow fan pattern in line with spray gun axis Slot Type Three angled slots in line with spray gun axis Application Top and bottom coating typically no in out part positioning Part Description Note 1102871 NOZZLE 45 degree flat spray Encore Fig...

Page 75: ...tor 1083206 26 mm Deflector 1083207 38 mm Deflector All deflectors include a 1098306 O ring Viton 3 mm x 1 1 mm wide Figure 7 6 Conical Nozzle and Deflectors Conical Nozzle Kit 1 2 3 Figure 7 7 Conical Nozzle Kit Item Part Description Quantity Note 1604828 KIT conical nozzle Encore 1 1 1083206 S DEFLECTOR 26 mm 1 2 1082060 S NOZZLE conical 1 3 1605861 S ELECTRODE HOLDER Conical 1 Conical Electrode...

Page 76: ... the lance extensions for installation instructions and repair parts Part Description Note 1093604 EXTENSION lance 150 mm Encore 1093605 EXTENSION lance 300 mm Encore 1600663 EXTENSION lance 600 mm Encore NOTE The electrode support holder for use with conical nozzles and deflectors must be used with a lance extension Pattern Adjuster Kit for Lance Extensions Use this pattern adjuster with the lanc...

Page 77: ...d length gun 1 Ion Collector Components for Lance Extensions To use the ion collector kit listed above with 150 mm or 300 mm Lance Extensions order one of the rods and the bracket listed below Refer to the instruction sheet shipped with the kit for installation instructions Item Part Description Quantity Note 189483 ROD ion collector 15 in 1 A 189484 ROD ion collector 21 in 1 B 1603939 BRACKET lan...

Page 78: ...57 04 E 2014 Nordson Corporation Controller Parts Front Panel and Internal Cabinet Ground Parts Illustration 1 2 3 5 4 7 6 9 10 11 12 13 Rear Panel Assembly See Figures 7 11 and 7 12 for parts 8 Figure 7 10 Controller Parts ...

Page 79: ...er packaged 1 3 982916 S SCREW flat socket M5 x 10 black 4 4 982636 S SCREW button socket M5 x 12 zinc 2 5 983127 S WASHER lock internal M5 zinc 2 6 983403 S WASHER lock split M4 steel zinc 4 7 982881 S SCREW pan head recessed M4 x 6 zinc 2 8 1045837 S SCREW pan head recessed M5 x 12 w lockwasher black 2 9 984702 S NUT hex M5 brass 1 10 983401 S WASHER lock split M5 steel zinc 1 11 983021 S WASHER...

Page 80: ... Part 1604857 04 E 2014 Nordson Corporation Rear Panel Parts Illustration 14 15 16 17 19 18 20 21 9 10 11 13 4 X 22 23 24 23 Manifold Assembly See Figure 7 12 this screw only 26 25 23 Figure 7 11 Rear Panel Parts ...

Page 81: ...an head recessed M5 x 12 with lockwasher black 4 18 1068715 S WASHER lock dished 10 1 19 972930 S PLUG push in 8 mm tubing plastic 1 20 972808 S CONNECTOR strain relief 1 2 in NPT 2 21 984192 S NUT lock 1 2 in NPT nylon 2 22 117549 S GASKET panel rear Encore LT controller 1 23 982824 S SCREW pan head recessed M3 x 8 with lockwasher black 10 24 1107696 S FILTER line RFI power 3A with 0 250 QD 1 25 ...

Page 82: ...6 S CONNECTOR male with internal hex 10 mm tube x 1 8 unithread 1 29 1062009 S CONNECTOR male with internal hex oval collar 4 mm tube x M5 1 30 972399 S CONNECTOR male with internal hex 6 mm tube x 1 8 unithread 1 31 1604486 S VALVE flow control 6 mm x 1 8 R 1 32 1108313 S MUFFLER exhaust 1 8 R 1 33 1107593 S GASKET manifold controller Encore LT 1 34 1107597 S REGULATOR electro pneumatic 2 35 1099...

Page 83: ...1 A NS 1107903 S KIT pickup tube collar Encore LT 1 A NS 1107913 KIT rail mount Encore LT 1 NS 1600437 KIT wall mount Encore LT NS 1067694 KIT ground bus bar ESD 6 position w hardware 1 C NS 1085679 KIT pump adapter hopper Encore 1 C NS 1082204 COUPLING pump Encore 1 C NS 972262 REDUCER 10 mm stem x 6 mm tubing 1 F NS 1600658 HANGER gun Encore LT 1 NS 1600566 KIT filter Encore LT 1 E NS 1600608 S ...

Page 84: ... powder delivery issues B Minimum order quantity is 50 ft C This tubing is used on VBF systems to provide fluidizing air from the bulkhead union to the pickup tube It is conductive and grounds the pickup tube to the cart body Do not replace with non conductive tubing D Minimum order quantity is 25 ft E Minimum order quantity is 100 ft System Options Part Description Quantity Note 1091429 KIT input...

Page 85: ... Encore 1 1083206 S DEFLECTOR assembly conical 26 mm Encore 1 1083201 S DEFLECTOR assembly conical 16 mm Encore 1 1082185 S NOZZLE cross cut 2 5 mm 90 degree Encore 1 1081656 S NOZZLE flat spray 2 5 mm Encore 1 1081659 S NOZZLE flat spray 6 mm Encore 1 1085679 S KIT pump adapter hopper Encore 1 1082204 S COUPLING pump Encore 1 768176 S TUBING powder antistatic 11 mm 43 in 6 ft A 900740 S TUBING po...

Page 86: ...Parts 7 18 Part 1604857 04 E 2014 Nordson Corporation ...

Page 87: ...Wiring Diagram 8 1 Part 1604857 04 E 2014 Nordson Corporation Section 8 Wiring Diagram ...

Page 88: ...Wiring Diagram 8 2 Part 1604857 04 E 2014 Nordson Corporation ...

Page 89: ...BROWN BLUE BLACK DC COM RED 24VDC BLUE BROWN 15 FT 4 6M POWER CORD BLACK BLACK NO 2 GND BROWN L L1 HOT LT BLUE N L2 NEUTRAL SK1 N BLUE BROWN N C BROWN LT BLUE GREEN YELLOW GREEN YELLOW GREEN YELLOW GND NO 1 ENCORE LT CONTROLLER MANIFOLD ASSY RELAY TO CTRLR A C POWER HARNESS GROUND JUMPER 2 GREEN W YELLOW CONTROLLER CABINET NO 4 GND GROUND JUMPER 3 GROUND JUMPER 1 VBF POWER CORD MOBILE SYSTEMS W VB...

Page 90: ...94 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 2009 Type of Protection Ambient Temperature 15_C to 40_C Ex II 2 D 2mJ Manual and Automatic Applicators Automatic Applicators are Type A P per EN50177 EX II 2 3 D Manual and Automatic Controllers EX II ...

Page 91: ...ZONE REV DESCRIPTION BY CHK RELEASE NO DATE 00 PRELIMINARY DC 07APR11 01 CABLE P N WAS 1102625 DC PE602493 13APR11 02 RELEASED TAL PE602493 03AUG11 ...

Page 92: ...ZONE REV DESCRIPTION BY CHK RELEASE NO DATE SEE SHEET 1 FOR REVISION HISTORY ...

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