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Troubleshooting

4-5

Part 1102771A

E

2010 Nordson Corporation

General Troubleshooting Chart

Problem

Possible Cause

Corrective Action

1. Uneven pattern,

unsteady or

inadequate powder

flow

Blockage in spray gun, powder

feed hose, or pump

1. Purge the spray gun. Remove

the nozzle and electrode

assembly and clean them.

2. Disconnect the powder feed hose

from the spray gun and blow out

the gun with an air gun.

3. Disconnect the feed hose from

the pump and gun and blow out

the feed hose. Replace the feed

hose if it is clogged with powder.

4. Disassemble and clean the pump.
5. Disassemble the spray gun.

Remove the inlet and outlet tubes

and elbow and clean them.

Replace components as

necessary.

Nozzle, deflector, or electrode

assembly worn, affecting pattern

Remove, clean, and inspect the

nozzle, deflector, and electrode

assembly. Replace worn parts as

necessary.
If excessive wear or impact fusion is

a problem, reduce the flow rate and

atomizing air flow.

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.

Improper fluidization of powder in

hopper

Increase the fluidizing air pressure.
If the problem persists, remove the

powder from the hopper. Clean or

replace the fluidizing plate if

contaminated.

iFlow module out of calibration

Perform the Re-Zero Procedure on

page 4-9.

2. Voids in powder

pattern

Worn nozzle or deflector

Remove and inspect the nozzle or

deflector. Replace worn parts.

Plugged electrode assembly or

powder path

Remove the electrode assembly and

clean it. Remove powder path if

necessary and clean it.

Electrode air wash flow too high

Adjust the needle valve at the power

unit to decrease the electrode air

wash flow.

Continued...

Содержание 1102771A

Страница 1: ...1102771A Issued 6 10 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 l...

Страница 2: ...ation Attn Customer Service 555 Jackson Street Amherst OH 44001 Notice This is a Nordson Corporation publication which is protected by copyright Original copyright date 2009 No part of this document m...

Страница 3: ...tions 2 2 Applicator Certification Label 2 2 Power Unit and Gun Interface Controllers Certification Label 2 2 System Connections 2 3 System Diagram 2 3 Controller Connections 2 3 Hopper Installation 2...

Страница 4: ...10 Select Charger Mode 3 10 Custom Mode 3 11 Classic Mode 3 11 Classic Standard STD Mode 3 11 Classic AFC Mode 3 12 Powder Flow Settings 3 13 Smart Flow Mode Settings 3 13 Setting Smart Flow Setpoint...

Страница 5: ...le Repair 5 15 Testing iFlow Modules 5 15 Flow to Pressure Chart 5 17 Solenoid Valve Replacement 5 17 Proportional Valve Cleaning 5 17 Proportional Valve Replacement 5 19 Parts 6 1 Introduction 6 1 Sy...

Страница 6: ...Table of Contents iv Part 1102771A E 2010 Nordson Corporation...

Страница 7: ...nd 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 m...

Страница 8: ...evices 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...

Страница 9: ...d 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 m...

Страница 10: ...Safety 1 4 Part 1102771A E 2010 Nordson Corporation...

Страница 11: ...owder pump and pick up tube 25 or 50 lb 11 3 or 22 7 kg powder feed hopper and all powder and air tubing required for operation Follow the procedures in this section to prepare the system for operatio...

Страница 12: ...azardous Location Rating for Applicator Zone 21 or Class II Division 1 S Hazardous Location Rating for Controls Zone 22 or Class II Division 2 S Dust Ingress Protection IP6X S Hopper Capacity 11 3 or...

Страница 13: ...black 6mm blue Power Unit Interface Module Hopper Pump Spray Gun Powder hose 6mm blue Board Relay disabled when controller configured for hopper system 10mm Filter Regulator 10mm Encore Controller Fig...

Страница 14: ...Cap if not used Net Manual System or Auxiliary Purge Air 6 mm Air Supply 10 mm Electrode Air Wash 4 mm Electrode Air Wash Needle Valve Atomizing Air 8 mm Flow Air 8 mm Ground Power Cord 15 ft Gun Cabl...

Страница 15: ...ground cable shipped with the system to the ground stud on the side of the fluidizing pan then plug the cable into the grounding socket on the cart base 6 Install the hose clamp over the end of the ve...

Страница 16: ...th pump adapter for the Encore pump The hopper is shipped with a pump adapter used for other types of pumps To mount the pump on the hopper 1 See Figure 2 5 Pull the pickup tube assembly out of the pu...

Страница 17: ...he powder feed hose onto the barbed throat holder Quick Disconnect Coupling Blue 8 mm Tubing Atomizing AIr Black 8 mm Tubing Flow Rate Air Throat Holder Powder Hose Figure 2 6 Pump Connections NOTE Th...

Страница 18: ...Feed the spray gun cable into the back of the tower and up through the top front This will allow you to bundle the cable with the purge and electrode air wash tubing 2 Connect the cable to the interf...

Страница 19: ...tting in the gun handle 4 mm Clear Electrode Air Wash Tubing 6 mm Black Purge Air Tubing Figure 2 8 Connecting Purge and Air Wash Tubing to the Spray Gun 3 Route the air tubing around the cart to the...

Страница 20: ...receptacle To quickly remove the hose adapter and hose from the gun press in on the bottom ends of the clips to release them from the groove Powder Tubing 11 mm or 1 2 in to Pump Barbed Hose Adapter...

Страница 21: ...7 6 bar 87 110 psi An optional input air kit with connectors couplings and 20 ft of 10 mm tubing is available Refer to the Parts section for the kit contents and ordering information NOTE Compressed a...

Страница 22: ...r cord to a customer supplied three prong plug Connect the plug to an electrical outlet that supplies the rated power Wire Color Function Blue N neutral Brown L hot Green Yellow GND ground System Grou...

Страница 23: ...plicator shall only be used with associated Encore Interface Control Unit and Encore Controller Power Unit 2 Equipment may only be used in areas of low impact risk Daily Operation NOTE The controller...

Страница 24: ...er NOTE If using Total Flow mode the total air setpoint must be greater than zero or you will not be able to set Flow Air and the gun will not spray powder Refer to page 3 13 for more information 8 Se...

Страница 25: ...the spray gun interface NOTE Unprogrammed preset numbers presets where all setpoints are zero are automatically skipped 4 Press the main trigger The system now sprays with the new preset settings Cha...

Страница 26: ...gun interface is disabled To shut off the controller power use the controller power switch on the power unit Electrode Air Wash Operation Electrode air wash air continually washes the spray gun electr...

Страница 27: ...ge the spray gun and press the standby button to turn off the interface and prevent accidental gun triggering 2 Gently pull the deflector off the electrode assembly If only changing the deflector inst...

Страница 28: ...the integral conical nozzle onto the electrode assembly and screw the nozzle nut clockwise until finger tight 4 Install a 16 19 or 26 mm deflector onto the electrode holder Deflector Electrode Assembl...

Страница 29: ...Blow off the gun and wipe it down with a clean cloth Pump Daily 1 Disconnect the pump air hoses and remove the pump from the pickup tube 2 Disassemble the pump and clean all parts using low pressure...

Страница 30: ...oint Button A Setpoint Help Button View Button Enter Button Figure 3 7 Controller Interface The Setpoint icons light to indicate the configured or selected setpoints Setpoints include Select Charge KV...

Страница 31: ...Section 4 Troubleshooting for help code troubleshooting general system troubleshooting resistance and continuity tests and system wiring diagrams Maintenance Timer Configuration and Versions Press the...

Страница 32: ...b The preset number increases from 1 to 20 then rolls over to 1 The setpoints for the selected preset are displayed when the gun is off Preset Button Figure 3 11 Preset Select Electrostatic Settings E...

Страница 33: ...crease or decrease the A setpoint The setpoint is automatically saved if it does not change for 3 seconds or when any button is pressed NOTE The default A range is 10 50 A The limits of the range can...

Страница 34: ...d Displays Classic AFC Mode Use the AFC mode to set A output limits In AFC mode you cannot adjust KV it is automatically set to 100 KV 1 To set the A setpoint press the A button The button LED lights...

Страница 35: ...er velocity is inversely related to transfer efficiency the higher the velocity the lower the transfer efficiency When making Smart Flow settings set the Total Flow setpoint first to obtain the desire...

Страница 36: ...button lights 2 Turn the knob to increase or decrease the setpoint The setpoint is automatically saved if it does not change for 3 seconds or when any button is pressed NOTE If Total Flow is set to z...

Страница 37: ...25 45 4 67 50 5 10 54 5 52 57 5 95 60 6 37 63 6 80 65 7 22 67 7 65 68 8 07 70 8 50 1 9 2 97 22 3 82 30 4 24 36 4 67 42 5 09 46 5 52 50 5 94 53 6 37 56 6 79 59 7 22 61 7 64 63 8 07 65 8 49 67 8 92 zing...

Страница 38: ...5 40 2 50 45 2 75 50 3 00 54 3 25 57 3 50 60 3 75 63 4 00 65 4 25 67 4 50 68 4 75 70 5 00 28 1 75 22 2 25 30 2 50 36 2 75 42 3 00 46 3 25 50 3 50 53 3 75 56 4 00 59 4 25 61 4 50 63 4 75 65 5 00 67 5 2...

Страница 39: ...re 3 19 Classic Mode Flow Air or Atomizing Air Setpoints S When the spray gun is not triggered the setpoints are displayed S When the spray gun is triggered the actual flows are displayed Controller C...

Страница 40: ...Help Codes 00 Enable 01 Disable 00 F10 Zero Reset Flow 00 Normal 01 Reset See Note below 00 F11 Gun Display Errors 00 Flashing 01 Disable 00 F12 A Lower Limit 00 10 A 01 5 A 02 1 A 00 F13 A Upper Lim...

Страница 41: ...n settings set F15 to F15 00 and press Enter All current preset and function settings are saved to memory To restore the saved preset and function settings set F15 to F15 01 and press Enter All the pr...

Страница 42: ...Operation 3 20 Part 1102771A E 2010 Nordson Corporation...

Страница 43: ...y the most common problems If you cannot solve a problem with the information given here contact your local Nordson representative for help Help Code Troubleshooting The Help icon in the Function Help...

Страница 44: ...nnections are secure but the fault persists replace the cable H15 Over Current Fault Cable or Gun Short This fault can occur if the gun tip touches a grounded part while spraying This fault will turn...

Страница 45: ...e help code appears disconnect the air tubing from the appropriate air output fitting and plug the fitting Clear the help codes If the code does not reappear then the proportional valve is stuck open...

Страница 46: ...olenoid open and close if it is functioning correctly H35 Vibratory Motor Valve Fault VBF units only Check the J9 connection for the relay inside the power unit If the harness becomes disconnected or...

Страница 47: ...zle deflector and electrode assembly Replace worn parts as necessary If excessive wear or impact fusion is a problem reduce the flow rate and atomizing air flow Damp powder Check the powder supply air...

Страница 48: ...gun cable Perform the Gun Cable Continuity Checks on page 4 11 If an open or short is found replace the cable Spray gun power supply shorted Perform the Power Supply Resistance Test on page 4 10 5 Po...

Страница 49: ...an system replace components if necessary Flow valve plugged H24 or H25 See Proportional Valve Cleaning in this section Air tubing kinked or plugged H24 or H25 Check flow and atomizing air tubing for...

Страница 50: ...et to zero If the total air is set to zero the flow percent cannot be adjusted Change the total flow to a non zero number Loose or defective trigger switch See Figure 4 7 Check for a loose trigger swi...

Страница 51: ...tings or from around the solenoid valves or proportional valves Re zeroing modules with leaks will result in additional errors 1 At the power unit disconnect the flow and atomizing air tubing and inst...

Страница 52: ...eter 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 4 2 Power Supply Resistance Test E...

Страница 53: ...2 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 POWER UNIT END FACE VIEW J3 J3 FACE VIEW DISPLAY MODULE CONNECTOR J3 1 WHITE J3 2 BLUE J...

Страница 54: ...R SUPPLY BLUE BROWN 2 3 4 5 6 6 2 1 3 4 5 J3 NET PWR 2 BLACK CAN 1 RED CAN 6 GREEN 24VDC 4 WHITE DC COM 1 RED CAN 2 BLACK CAN 4 GREEN 24VDC 3 WHITE DC COM 5 GRAY DRAIN GND FLOW CONTROLLER PCA 2 1 J10...

Страница 55: ...N CAN 1 ORANGE 6 GREEN 5 YELLOW 12VDC GROUND FEEDBACK 4 WHITE 3 RED LIN OSC 2 BLACK DC COM J6 J7 J2 J3 1 2 BLACK DC COM RED OSC WHITE LIN YELLOW FEEDBACK ORANGE 12VDC NET RECEPTACLE GUN RECEPTACLE CON...

Страница 56: ...Troubleshooting 4 14 Part 1102771A E 2010 Nordson Corporation...

Страница 57: ...ch and disconnect them 5 Carefully remove the adhesive support pad and the trigger switch header from the display module 6 If the adhesive support pad remains stuck to the trigger switch header carefu...

Страница 58: ...dule ground connector A is not used for this version of the gun 6 Gently fold the trigger switch ribbon cable and display module cable into the gun and install the display module onto the gun 7 Slide...

Страница 59: ...nstallation 1 Slide the new power supply into the upper cavity of the gun body guiding the gun body ribs between the grooves on the power supply 2 Press on the end of the power supply to ensure that t...

Страница 60: ...3A Electrode holder and electrode 4 Filter assembly 4A Electrode air wash tubing 5 Gun Body 6 Power supply multiplier 7 Gasket 8 Bulkhead 9 Display module 10 Hook 11 Bezel 11A M3 x 35 screws 12 M3 x 2...

Страница 61: ...rom the controller interface module 4 Remove the display module and power supply as described in Display Module Replacement and Power Supply Replacement 5 See Figure 5 4 Remove the M5 x 10 nylon screw...

Страница 62: ...eparating the Base from the Handle 4A Clear 4 mm tubing 12 M3 x 20 screws 13 Elbow 20 Dual barbed fitting 22 Handle base 23 Inlet tube 11 See Figure 5 7 Gently pull the ground pad 27 away from the han...

Страница 63: ...powder tube 23 from the base with a twisting motion 17 Carefully remove the retaining ring 19 from the cable it can spring off and get lost then remove the cable 28 from the base 19 27 25 26 22 17 16...

Страница 64: ...mounting flat of the right handle half 25 up against the tabs and bottom flat Press firmly on the switch to secure it in place 4 Assemble the actuator 18 on the main trigger 17 boss Note the orientati...

Страница 65: ...e base is about 1 5 2 inches from the bottom of the handle assembly 7 Connect the 4 mm clear tubing part of filter assembly item 4 to the barbed fitting 20 in the handle base 28 Clear tubing 23 Tube G...

Страница 66: ...e power supply 12 Press on the end of the power supply to ensure that the contact tip at the end of the gun body is firmly seated against the brass contact inside the power supply end 13 See Figure 5...

Страница 67: ...stallation 13 Elbow 14 Outlet powder tube 19 See Figure 5 4 Install the M5 x 10 flat head nylon screw into the gun body to secure it to the handle 20 Align the inside end of the powder tube with the e...

Страница 68: ...connect 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 sensitive d...

Страница 69: ...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 ground...

Страница 70: ...ule Repair and Regulator Replacement for repair procedures 3 4 2 1 6 5 7 8 Figure 5 17 Sub Panel Parts Replacement 1 Regulator 2 iFlow module 3 Relay VBF 4 Power supply 5 Line filter 6 Capacitor VBF 7...

Страница 71: ...electrostatic sensitive device ESD To prevent damage to the board when handling it wear a grounding wrist strap connected to ground Handle the board only by its edges Repair of the flow module is lim...

Страница 72: ...tput pressure at different flow settings If the manometer reading is within the acceptable range then the digital flow module is working correctly If the reading is not within the acceptable range ref...

Страница 73: ...e valve body and lift the valve off the manifold Make sure the O rings furnished with the new valves are in place before installing the new valve on the manifold Proportional Valve Cleaning See Figure...

Страница 74: ...iFlow Module Repair Solenoid Valve Replacement and Proportional Valve Cleaning or Replacement 1 Circuit board 2 Nut coil to proportional valve 2 3 Coil proportional valve 2 4 Long screws valve to mani...

Страница 75: ...body to the manifold with the long screws making sure the arrow on the side of the body points toward the outlet fittings 9 Install the coil over the valve stem with the coil wiring pointing toward t...

Страница 76: ...Repair 5 20 Part 1102771A E 2010 Nordson Corporation...

Страница 77: ...and hopper parts and repair information Encore System Operator Card 1088668 Encore Generation II Powder Feed Pump 1095927 Encore 150 and 300 mm Lance Extensions 1093657 Pattern Adjuster Kit for Lance...

Страница 78: ...rdson Corporation Spray Gun Parts 1 2 3 4 5 4 6 7 8 15A 9 10 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 27A 27B 3A 3B 29 30 29A 11A 31 31A 14A 14B 12 23B 23A Figure 6 1 Exploded View of Encore...

Страница 79: ...ube handgun 1 F 14 1085024 S KIT powder outlet tube Encore 1 F 14A 1081785 S S O ring silicone 0 468 x 0 568 x 0 05 in 1 14B 941113 S S O ring silicone 0 438 x 0 625 x 0 094 in 1 15 1101872 S KIT trig...

Страница 80: ...t 3 8 in ID AR C NS 1085168 CABLE 6 wire shielded handgun 6 meter extension 1 D NOTE A Standard flat spray nozzle and conical nozzle and deflector shipped with spray gun Refer to the following pages f...

Страница 81: ...nt 1 14A 1081785 S O ring silicone 0 468 x 0 568 x 0 05 in 1 14B 941113 S O ring silicone 0 438 x 0 625 x 0 094 in 1 NS 1093604 EXTENSION lance 150 mm Encore 1 NS 1093605 EXTENSION lance 300 mm Encore...

Страница 82: ...al NOTE All deflectors include the O ring item 23A listed in the spray gun parts list 1082060 Conical Nozzle 1083201 16 mm Deflector 1083205 19 mm Deflector 1083206 26 mm Deflector 1083207 38 mm Defle...

Страница 83: ...r Kit The pattern adjuster kit includes an integral conical nozzle 16 19 and 26 mm deflectors can be used with the kit The deflectors are not included with the kit they must be ordered separately 1098...

Страница 84: ...Parts 6 8 Part 1102771A E 2010 Nordson Corporation Controller Parts Interface Parts Exploded View 1 2 3 4 9 7 8 10 11 12 13 5 6 13 12 11 10 18 14 15 GUN NET 16 17 Figure 6 6 Interface Parts...

Страница 85: ...lock split M4 steel zinc 8 7 982636 S SCREW button socket M5 x 12 zinc 2 8 983127 S WASHER lock internal M5 zinc 2 9 982286 S SCREW flat slotted M5 x 10 zinc 4 10 984702 S NUT hex m5 brass 2 11 98340...

Страница 86: ...ts 6 10 Part 1102771A E 2010 Nordson Corporation Power Unit Parts Exploded View 1 22 21 20 19 12 11 10 8 16 14 2 3 4 5 6 8 9 10 11 12 20 19 13 17 7 18 7 15 3 3 3 7 23 23 24 25 Figure 6 7 Power Unit Pa...

Страница 87: ...ock split M5 steel zinc 3 12 984702 S NUT hex M5 brass 3 13 1027067 S CORD power 15 ft 4 6 meters 1 14 288804 S FUSE HOLDER panel mount 5 x 20 2 15 1009090 S FUSE time delay 215 series 3 15A 5 x20mm 2...

Страница 88: ...iFlow Encore packaged 1 1 1099288 S VALVE solenoid 3 way w connector 4 2 1027547 S VALVE proportional solenoid sub base 2 3 1030873 S VALVE check M8 tube x 1 8 in unithread 3 4 972399 S CONNECTOR male...

Страница 89: ...nstalled in power unit fluidizing air output fitting D Install in 10 mm elbow in hopper fluidizing pan E Plugs unused port in system air filter regulator output fitting F To replace the original Festo...

Страница 90: ...lement for your filter regulator Elements are not interchangeable Pump Parts Each Encore pump is shipped with a manual containing installation repair and parts information Encore pump manuals can also...

Страница 91: ...1 2009 Principles This product has been manufactured according to good engineering practice The product specified conforms to the directive and standards described above Type of Protection Ambient Tem...

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