Encore 1102771A Customer Product Manual
EncorerMobile Powder Spray
System with Feed Hopper
Customer Product Manual
Part 1102771A
Issued 6/10
For parts and technical support, call the
Finishing Customer Support Center at (800) 433-9319.
This document is subject to change without notice.
Check http://emanuals.nordson.com/finishing for the latest version.
NORDSON CORPORATION AMHERST, OHIO USA
C
APPROVED
FM
US
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 2009. 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.
Part 1102771A
E 2010 Nordson Corporation
Table of Contents i
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...............................................
System Setup 2-1..........................................
Introduction 2-1.............................................
Specifications 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 2-5......................................
Pump Installation 2-6........................................
Pump Mounting 2-6.......................................
Pump Connections 2-7....................................
Spray Gun Connections 2-8..................................
Gun Cable 2-8...........................................
Spray Gun Air Tubing Connections 2-9......................
Spray Gun Powder Tubing Connection 2-10...................
Bundling Tubing and Cable 2-10.............................
System Air and Electrical Connections 2-11.....................
System Air Supply 2-11....................................
Electrical Connections 2-12.................................
System Ground 2-12.......................................
E 2010 Nordson Corporation
Part 1102771A
ii
Table of Contents
Operation 3-1..............................................
European Union, ATEX, Special Conditions for Safe Use 3-1.....
Daily Operation 3-1.........................................
Startup 3-1..............................................
Factory Set Presets 3-2...................................
Spray Gun Operation 3-3..................................
Changing Presets with the Settings Trigger 3-3.............
Changing Powder Flow with the Settings Trigger 3-3........
Purging the Gun 3-3....................................
Standby Button 3-4.......................................
Electrode Air Wash Operation 3-4..........................
Changing Flat Spray Nozzles 3-4...........................
Changing Deflectors or Conical Nozzles 3-5..................
Installing the Optional Pattern Adjuster Kit 3-6................
Shutdown 3-6...............................................
Maintenance 3-7............................................
Using the Controller Interface 3-8.............................
Help Codes 3-9.............................................
Maintenance Timer, Configuration, and Versions 3-9.............
Preset Setup 3-10...........................................
Selecting Presets 3-10.....................................
Electrostatic Settings 3-10....................................
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 Setpoints 3-14.........................
Smart Flow Settings -- Metric Units 3-15....................
Smart Flow Settings -- English Units 3-16...................
Classic Flow Mode Settings 3-17............................
Controller Configuration 3-17..................................
Opening the Function Menu and Making Settings 3-17.........
Vibratory Box Feeder On Continuously 3-18...................
Saving and Loading Preset and Function Settings 3-19.........
Setting the Number of Presets 3-19..........................
Part 1102771A
Troubleshooting 4-1........................................
Help Code Troubleshooting 4-1...............................
Viewing Help Codes 4-1...................................
Clearing Help Codes 4-1..................................
Help Code Troubleshooting Chart 4-2.......................
General Troubleshooting Chart 4-5............................
Re-Zero Procedure 4-9....................................
Spray Gun Power Supply Resistance Test 4-10..................
Electrode Assembly Resistance Test 4-10.......................
Gun Cable Continuity Test 4-1 1................................
Controller Interconnect Cable Test 4-11.........................
System Wiring Diagrams 4-12.................................
E 2010 Nordson Corporation
Table of Contents iii
Repair 5-1.................................................
Spray Gun Repair 5-1.......................................
Display Module Replacement 5-1...........................
Display Module Removal 5-1............................
Display Module Installation 5-1...........................
Power Supply Replacement 5-3............................
Power Supply Removal 5-3..............................
Power Supply Installation 5-3............................
Trigger Switch, Gun Cable, and Handle Replacement 5-4......
Gun Disassembly 5-5...................................
Gun Re-assembly 5-8..................................
Interface Module Repair 5-12..................................
Power Unit Repair 5-13.......................................
Removing the Sub Panel 5-13..............................
Sub Panel Components 5-14................................
Regulator Replacement 5-14................................
iFlow Module Repair 5-15...................................
Testing iFlow Modules 5-15...............................
Flow to Pressure Chart 5-17..............................
Solenoid Valve Replacement 5-17.........................
Proportional V alve Cleaning 5-17..........................
Proportional V alve Replacement 5-19......................
Parts 6-1...................................................
Introduction 6-1.............................................
System Part Numbers 6-1...................................
Spray Gun Parts 6-2........................................
Spray Gun Options 6-5......................................
Miscellaneous Spray Gun Options 6-5.......................
Flat Spray Nozzles 6-5....................................
Conical Nozzle and Deflectors 6-6..........................
Optional Cross Cut Nozzles 6-6............................
Optional Pattern Adjuster Kit 6-7...........................
Controller Parts 6-8.........................................
Interface Parts Exploded View 6-8..........................
Interface Parts List 6-9....................................
Power Unit Parts Exploded View 6-10........................
Power Unit Parts List 6-11..................................
iFlow Module Parts 6-12....................................
System Components and Parts 6-13...........................
Powder Hose and Air Tubing 6-13...........................
Options 6-14..............................................
Pump Parts 6-14..........................................
Pump Adapter Kit 6-14.....................................
E 2010 Nordson Corporation
Part 1102771A
iv
Table of Contents
Part 1102771A
E 2010 Nordson Corporation
Introduction
Safety
Section 1
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, is
accessible to all persons operating or servicing equipment.
1-1
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 U se
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 safety guards or interlocks
S using incompatible or damaged parts
S using unapproved auxiliary equipment
S operating equipment in excess of maximum ratings
Regulations and A pprovals
E 2010 Nordson Corporation
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.
Part 1102771A
1-2
Safety
Personal Safety
To prevent injury follow these instructions.
S Do not operate or service equipment unless you are qualified.
S Do 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.
S Keep 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.
S Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or
servicing pressurized systems or components. Disconnect, lock out,
and tag switches before servicing electrical equipment.
S Obtain and read Material Safety Data Sheets (MSDS) for all materials
used. Follow the manufacturer’s instructions for safe handling and use
of materials, and use recommended personal protection 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
materials are being used or stored.
S Provide adequate ventilation to prevent dangerous concentrations of
volatile materials or vapors. Refer to local codes or your material MSDS
for guidance.
S Do not disconnect live electrical circuits while working with flammable
materials. Shut off power at a disconnect switch first to prevent
sparking.
S Know 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.
S Clean, maintain, test, and repair equipment according to the instructions
in your equipment documentation.
S Use only replacement parts that are designed for use with original
equipment. Contact your Nordson representative for parts information
and advice.
Part 1102771A
E 2010 Nordson Corporation
Grounding
Safety
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.
1-3
S All 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.
S Equipment 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.
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 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.
S Shut off electrostatic power supplies and ground gun electrodes before
making adjustments or cleaning powder spray guns.
S Connect all disconnected equipment, ground cables, and wires after
servicing equipment.
Action in the Event of a Malfunction
Disposal
E 2010 Nordson Corporation
If a system or any equipment in a system malfunctions, shut off the system
immediately and perform the following steps:
S Disconnect and lock out electrical power. C lose pneumatic shutoff
valves and relieve pressures.
S Identify the reason for the malfunction and correct it before restarting the
equipment.
Dispose of equipment and materials used in operation and servicing
according to local codes.
Part 1102771A
1-4
Safety
Part 1102771A
E 2010 Nordson Corporation
Introduction
System Setup
2-1
Section 2
System Setup
See Figure 2-1. The Encore Mobile Powder Spray System is a complete
manual powder spray system mounted on a sturdy four-wheel cart. The
system includes a manual spray gun, two-piece controller, powder 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 operation.
6
5
1
4
2
3
E 2010 Nordson Corporation
Figure 2-1 Encore Mobile Powder Spray System with Powder Feed Hopper
1. Encore spray gun
2. Powder feed hopper
3. Cart tower
Note: Power unit portion of controller is installed in rear of cart tower.
4. Encore powder feed pump
5. Fluidizing air regulator
6. Spray gun controller
Part 1102771A
2-2
System Setup
Specifications
Model Input Rating Output Rating
ENCORE Applicator +/-- 19 VAC, 1 A 100 KV, 100 A
ENCORE Interface Control Unit 24 VDC, 2.75 A +/-- 19 VAC, 1A
ENCORE Controller Power Unit 100--240 VAC, 50/60 Hz, 85 VA 24 VDC, 2.75 A
S Input Air: 6.0--7.6 bar (87--110 psi), <5 particulates, dew point <10 _C
(50 _F)
S Max Relative Humidity: 95% non-Condensing
S Ambient Temperature Rating (Encore System): +15 to +40 _C
(59--104 _F)
S Hazardous 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 22.7 kg (25 or 50 lb)
Applicator Certification Label
C
US
APPROVED
Power Unit and Gun Interface Controllers Certification
Label
ELECTROSTATIC HAND--HELD POWDER
SPRAY EQUIPMENT TYPE ENCORE
NORDSON CORPORATION, AMHERST, OHIO U.S.A.
SIRA08ATEX5010XEN 50 050
Ta: + 15_CTO+40_C
PWR UNIT OUTPUT: Vo=24VDC Io=2.75A
INTERFACE OUTPUT: Vo=19VAC Io=1A
Ex tD A22 IP6X
Vn=100--240 VAC, fn = 50/60 Hz
T60_C
r
Pn=85 VA
Part 1102771A
1180 II 3 (2) D
DO NOT OPEN WHEN EXPLOSIVE ATMOSPHERE IS PRESENT
E 2010 Nordson Corporation
System Connections
System Diagram
NOTE: This diagram does not show system grounds. The system and its
components must all be connected to a true earth ground.
System Setup
2-3
Encore Controller
Filter/Regulator
Input Air
10mm
10mm
AC Power Cord
Reg
85 PSI
Interface
Module
CAN/+24V
Power Unit
Main Control
Air Wash Air
Purge Air
Atomizing Air
iFlow Module
Power
Supply
Switch
Fuses
Board
Flow-Rate Air
Relay*
Fluidizing Air
Gun cable
4mm clear
6mm black
8mm blue
8mm black
6mm blue
Fluidizing Air
Gauge and Regulator
60
40
4
3
80
2
5
20
6
1
0
7
0
BAR
100
psi
* Relay disabled when controller
configured for hopper system
Spray Gun
Powder hose
Pump
Hopper
6mm blue
Figure 2-2 Encore Manual Powder System Block Diagram
Controller Connections
E 2010 Nordson Corporation
The Encore Spray Gun Controller is a two piece unit, consisting of a
interface module and a power unit, connected by a network/power
interconnect cable.
The power unit houses a 24Vdc power supply, circuit board, and iFlowr air
control manifold.
The interface module houses the operator interface panel, which contains
the displays and controls used to make controller function settings and
spray settings, and the spray gun driver board.
Part 1102771A
2-4
System Setup
Ground
Flow Air
(8 mm)
Atomizing Air
(8 mm)
Electrode Air Wash
Needle Valve
Electrode Air Wash
(4 mm)
Air Supply
(10 mm)
Purge Air (6 mm)
Net
(Manual System)
or Auxiliary
POWER UNIT
INTERFACE MODULE
System Power Switch
L1
(Brown)
L2
(Blue)
GND
(Green/Yellow)
Power Cord
(15 ft)
VBF Power
(Cap if not used)
Fluidizing Air
Check Valve
(8 mm, reduced to 6-mm)
Network/Power
Interconnect
Cable
Figure 2-3 Encore Gun Controller Connections
Gun Cable
(to Gun)
Ground
Part 1102771A
E 2010 Nordson Corporation
Hopper Installation
1. Unclamp the hopper lid and remove the vent hose and hose clamps.
2. Place the hopper on the cart platform so that the bottom of the fluidizing
3. Connect the 10-mm stem x 6-mm tube reducer to the 10-mm elbow
4. Connect the 6-mm blue fluidizing air tubing to the reducer.
5. Connect the ring-tong terminal on the 1-ft green/yellow ground cable
6. Install the hose clamp over the end of the vent hose and connect the
NOTE: Before turning on the controller interface, route the other end of the
vent hose into the spray booth. This prevents the very fine powder particles
in the vented fluidizing air from contaminating the spray room.
System Setup
2-5
pan fits into the cutout in the cart platform.
fitting on the fluidizing pan.
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.
hose to the vent stack on the lid. Tighten the clamp to secure the hose.
Vent Stack
Ground
Plug/Socket
Vent Hose
Ground Stud
Fluidizing Air
Fitting
E 2010 Nordson Corporation
Ground
Cable
Figure 2-4 Hopper Installation
Hopper
Fluidizing
Pan
Reducer
Fluidizing
Air
Tubing
Part 1102771A
2-6
System Setup
Pump Installation
Pump Mounting
CAUTION: Pump adapter O-rings are conductive silicone, to provide a
ground connection between the pump body and the pickup tube or hopper
lid. Do not replace these O-rings with non-conductive O-rings.
The system is shipped with 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 pump mount.
2. Unscrew the adapter from the pickup tube.
3. Screw the new adapter onto the pickup tube.
4. Re-install the pickup tube assembly into the pump mount then install the
pump into the new adapter with a slight twisting motion.
Replace
With This
Adapter
Remove
This
Adapter
Pickup Tube
Part 1102771A
Figure 2-5 Pump Mounting
E 2010 Nordson Corporation
Pump Connections
System Setup
2-7
1. Plug the blue atomizing air and black flow-rate air tubing into the pump
tube fittings as shown in Figure 2-6.
2. Push the powder feed hose onto the barbed throat holder.
Blue 8-mm Tubing (Atomizing AIr
Quick-Disconnect Coupling
Black 8-mm Tubing
(Flow-Rate Air)
Figure 2-6 Pump Connections
)
Throat Holder
Powder Hose
NOTE: The pump is equipped with quick-connect couplings that allow you
to quickly disconnect the air tubing when cleaning or repairing the pump.
Pull back on the knurled coupling rings to disconnect them.
E 2010 Nordson Corporation
Part 1102771A
2-8
System Setup
Spray Gun Connections
Unpack the spray gun. Uncoil the spray gun cable and the included 4-mm
clear and 6-mm black air tubing. Make the following connections:
Gun Cable
SeeFigure2-7.
1. 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 interface module receptacle. The cable plug
and receptacle are keyed.
3. Thread the cable nut onto the receptacle and tighten the nut securely.
Gun Cable
Figure 2-7 Connecting the Gun Cable to the Controller Interface Module
Part 1102771A
Net Cable
(To Power Unit)
E 2010 Nordson Corporation
Spray Gun Air Tubing Connections
See Figures 2-8 and 2-9.
Clear 4-mm and black 6-mm air tubing is shipped with the spray gun.
1. Connect the 6-mm black air tubing to the quick-disconnect fitting in the
gun handle.
2. Connect the 4-mm clear electrode air wash tubing to the barbed fitting in
the gun handle.
4-mm Clear
Electrode Air Wash
Tubing
System Setup
2-9
Figure 2-8 Connecting Purge and Air Wash Tubing to the Spray Gun
3. Route the air tubing around the cart to the rear of the tower.
4. Connect the 4-mm clear electrode air wash tubing to the electrode air
wash quick-disconnect fitting.
5. Connect the 6-mm black purge air tubing to the purge air
quick-disconnect fitting.
4-mm Clear
Electrode Air
Wash Tubing
6-mm Black
Purge Air Tubing
6-mm Black
Purge Air Tubing
Figure 2-9 Connecting Purge and Air Wash Tubing to the Controller
E 2010 Nordson Corporation
Part 1102771A
2-10
System Setup
Spray Gun Powder Tubing Connection
See Figure 2-10.
Push the barbed hose adapter into the end of the powder feed hose, then
plug the adapter into the receptacle in the bottom of the spray gun handle.
Make sure the adapter clips snap into the groove in the 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.)
Make sure clips
are seated in
groove
Press IN on
clips when
installing or
removing
adapter
Figure 2-10 Connecting the Powder Tubing to the Spray Gun
Bundling Tubing and Cable
Use the sections of black spiral wrap supplied with the system to bundle
together the spray gun cable, air tubing, and powder feed tubing.
Barbed Hose
Adapter
Powder Tubing
11-mm or
to Pump
1
/2in.
Part 1102771A
E 2010 Nordson Corporation
System Air and Electrical Connections
System Air Supply
See Figure 2-11. Connect 10-mm air tubing from your compressed air
supply to the system air filter in the power unit cabinet. The air supply
pressure should be 6.0--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 air should be supplied from an air drop equipped with
a self-relieving shutoff valve. The air must be clean and dry. A refrigerant
or desiccant-type air drier and air filter/separators are recommended.
System Setup
2-11
Air Filter
Regulator
Figure 2-11 System Air Supply Connection
10-mm
Air Tubing
E 2010 Nordson Corporation
Part 1102771A
2-12
System Setup
Electrical Connections
System Ground
The controller is rated for 100--240 Vac at 50/60 Hz, single phase.
Wire the system power 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)
See Figure 2-12. Use the ground cable attached to the lower ground stud
on the cart to ground the system to a true earth ground.
Part 1102771A
Figure 2-12 System Ground Connection
E 2010 Nordson Corporation
Operation
3-1
Section 3
Operation
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
WARNING: This equipment can be dangerous unless it is used accordance
with the rules laid down in this manual.
WARNING: All electrically conductive equipment in the spray area must be
grounded. Ungrounded or poorly grounded equipment can store an
electrostatic charge which can give personnel a severe shock or arc and
cause a fire or explosion.
European Union, ATEX, Special Conditions for Safe Use
1. The Encore Manual Applicator 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 is shipped with a default configuration that will allow
you to start spraying powder as soon as you finish setting up the system.
Refer to Controller Configuration on page 3-17 for a list of the defaults and
instructions on how to change them, if desired.
Startup
1. Turn on the spray booth exhaust fan.
2. Make sure the vent hose is connected to the vent stack on the hopper
lid and routed into the spray booth.
3. Turn on the system air supply.
4. Remove the black rubber fill plug from the hopper lid and fill the hopper
half full of powder.
E 2010 Nordson Corporation
NOTE: Do not fill the hopper more than half full. The fluidizing air will
cause the powder to increase in volume.
Part 1102771A
3-2
Operation
Startup (contd)
Controller
Power
Switch
Figure 3-1 System Controls
Fluidizing Air
Regulator/Gauge
On
Off
Controller
Interface
Standby
Button
Spray
Gun
Interface
5. Make sure the spray gun is not triggered, then turn on controller power.
The displays and icons on the controller interface and gun interface will
light.
6. The fluidizing air turns on when the interface is turned on. Adjust the
fluidizing air pressure to 0.3--0.7 bar (5--15 psi). The pressure should be
just enough so the powder in the hopper “boils” gently. Fluidize the
powder for 5--10 minutes before spraying powder.
7. Point the spray gun into the booth and press the trigger to start spraying
powder.
NOTE: If using Total F low 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. R efer to page 3-13 for more information.
8. Select the desired preset and start production.
The controller interface displays actual output when the gun is spraying and
the current preset setpoints when the gun is off.
Factory Set Presets
Presets are recipes with electrostatic and powder flow setpoints for a
particular part or application. 20 presets are available. Presets 1--3 are
setup for you. Refer to Preset Setup on page 3-10 for preset setting
instructions.
Setpoints
Preset Electrostatic Output and Powder Flow
1 Max kV, 150 g/min (20 lb/hr) 100 30 45 3.0
2 Max kV, 300 g/min (40 lb/hr) 100 30 75 3.0
3 Select Charge 3 (deep recess), 150 g/min (20 lb/hr) 100* 60* 45 3.0
* Select Charge Mode settings are factory set and cannot be changed.
kV A %
Part 1102771A
E 2010 Nordson Corporation
Spray Gun Operation
Operation
3-3
The spray gun interface and settings trigger allow you to change presets or
powder flow settings, or purge the gun as needed, without using the
controller Interface.
Preset
Mode
Icon
Display
Mode
Button
Spray Gun
Interface
Figure 3-2 Gun Controls
Flow
Mode Icon
Purge
Button
Settings
Trigger
Increase/On
Decrease/Off
Main Trigger
Changing Presets with the Settings Trigger
1. See Figure 3-2. Release the main trigger. Presets cannot be changed
while the gun is triggered on.
2. Press the Mode button until the Preset Mode Icon is lit. The display
shows the current preset number.
3. Push the settings trigger up or down until the desired preset number is
displayed on 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.
Changing Powder Flow with the Settings Trigger
1. See Figure 3-2. Press the Mode button until the Flow Mode icon is lit.
2. Push the settings trigger up or down to change the flow setpoint. This
can be done without releasing the main trigger.
The powder flow immediately changes. The new flow setpoint is
displayed on both the spray gun interface and the controller interface.
NOTE: In Tot al 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.
Purging the Gun
1. See Figure 3-2. Point the gun into the booth and release the main
trigger.
2. Press the Purge button. The purge will continue as long as the purge
button is pressed.
E 2010 Nordson Corporation
Part 1102771A
3-4
Operation
Standby Button
NOTE: If the settings trigger is configured for Purge, then pressing up or
down on the settings trigger purges the gun. Refer to Controller
Configuration on page 3-17 for configuration instructions.
Purge the gun periodically to keep the powder path inside the spray gun
clean. The purge length and frequency needed depend on the application.
NOTE: The purge air only cleans the spray gun powder path. To purge the
powder hose, disconnect it from the pump and the gun, place the gun end
inside the booth, and blow it out from the pump end with compressed air.
Use the Standby button shown in Figure 3-1 to shut off the interface and
disable the spray gun during breaks in production. When the controller
interface is off the spray gun cannot be triggered, and the spray 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 electrode to
prevent powder from collecting on it. Electrode air wash turns on and off
automatically when the spray gun is triggered on and off.
The air flow needle valve on the power unit is set at the factory for the most
common applications (1be adjusted if needed.
Electrode Air Wash
Figure 3-3 Electrode Air Wash Needle Valve Location
Changing Flat Spray Nozzles
WARNING: Release the spray gun trigger, turn off the interface, and
ground the electrode before performing this procedure. Failure to observe
this warning could result in a severe electrical shock.
1
Needle Valve
/2turns CCW from fully closed position), but can
Part 1102771A
1. Purge the spray gun and press the standby button to turn off the
interface and prevent accidental gun triggering.
2. Unscrew the nozzle nut counterclockwise.
3. Pull the flat spray nozzle off the electrode assembly.
E 2010 Nordson Corporation
Operation
3-5
NOTE: Re-install the electrode 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 bend the electrode wire.
5. Screw the nozzle nut onto the gun body clockwise until finger-tight.
Nozzle Nut
Figure 3-4 Changing a Flat Spray Nozzle
Flat Spray Nozzle
Changing Deflectors or Conical Nozzles
WARNING: Release the spray gun trigger, turn off the interface, and
ground the electrode before performing this procedure. Failure to observe
this warning could result in a severe electrical shock.
1. Purge 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, 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: If the electrode assembly comes out of the powder outlet tube,
re-install it.
5. Install a new conical nozzle on the electrode assembly. The nozzle is
keyed to the electrode assembly.
Electrode Assembly
Electrode Holder
Deflector
Figure 3-5 Changing a Conical Nozzle
E 2010 Nordson Corporation
6. Screw the nozzle nut onto the gun body clockwise until finger-tight.
7. Install a new deflector on the electrode assembly. Do not bend the
electrode wire.
Electrode
Nozzle Nut
Assembly
Nozzle
Part 1102771A
3-6
Operation
Installing the Optional Pattern Adjuster Kit
An optional pattern adjuster kit with integral conical nozzle can be installed
in place of a standard flat spray or conical nozzle.
NOTE: Deflectors are not included with the pattern adjuster kit; they must
be ordered separately. The 38-mm deflector cannot be used with the kit.
1. Remove the deflector, nozzle nut, and conical nozzle, or the nozzle nut
and flat spray nozzle.
2. Blow off the electrode assembly.
3. Install 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.
Electrode
Assembly
Figure 3-6 Pattern Adjuster Kit Installation
Pattern
Adjuster Kit
Shutdown
1. Purge the spray gun by pressing the Purge button until no more powder
is blown from the gun.
2. Press the standby button to turn off the spray gun and interface.
3. Turn off the system air supply and relieve the system air pressure.
4. If shutting down for the night or a longer period of time, move the power
unit switch to the OFF position to shut off system power.
5. Perform the Daily Maintenance procedures on page 3-7.
Electrode Holder
Deflector
Part 1102771A
E 2010 Nordson Corporation
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