© 2021 Nordson Corporation 1608259-03Installation GuidePart Number 1608259-03© 2021 Nordson CorporationOriginal Copyright Date 2015Issued: 05/2021Encore™ HD MobilePowder CoatingSystemFollow the safety, operation, and maintenance instructions in the product manual.Refer to the Encore HD manual 1605707 for additional information.ENCORE HD MOBILE SYSTEM COMPONENTSComponents Required ForInstallationPreassembled Mobile SystemEncore® HD Spray Gun with Cable4-mm Clear Air Tubing6-mm Blue Air Tubing8-mm Powder Hose12-mm Blue Air TubingTube CuttersBarbed Fitting (Pickup Tube)Spiral WrappingTools Required for InstallationScissorsTube Cutters (included)ScrewdriverPliersWrenchOptional ComponentsRail Mount BracketGrounding BlockAdapter

Nordson Encore Installation Manual

Safety

Personal Safety

Grounding

Description

Components List

Optional Component List

Feed Center Control Panel

Lance Assemblies

Lance Lift Operation

Level Sensor Modules

Purge Manifold

Sieve

Pneumatic Panel Components

Control Manifold Functions

Optional HD Tube Assembly

Optional Powder Hoppers

Specifications

Electrical Requirements

Air Pressures

Installation

Lift Cylinder Installation

Electrical Connections

Powder Pump Installation and Connections

Pump Flow and Atomizing Air Tubing

Lance Fluidizing Air Connection

Reclaim and Virgin Powder Feed Options

Lift Cylinder Proximity Switch Adjustment

Level Sensor Position Adjustment

Damper Adjustment

Setup

Changing Function Values

Level Sensor Programming

Empty (No Powder) Programming

Operational Faults (Red LED Flashing)

Air Pressure Settings

Operation

Controls

Feed Center Operation

Transfer Pump Manual Purging

Color Change Operation

Color Change Procedure

Maintenance

Periodic Maintenance

Troubleshooting

Repair

Latch Pawl Replacement

Latch Replacement

Latch Pawl Adjustment

Clamping Cylinder Replacement

Lift Cylinder Replacement

Cylinder Cushion Stop Adjustment

Feed Hopper Fluidizing Plate Replacement

lb Feed Hopper Fluidizing Plate Replacement

Vibratory Table Motor Weight Adjustment

Hz Motor Weight Adjustment

Parts

Powder Feed Center Parts

Lift Assembly Parts

Lance Assembly Parts

Fluidizing Latch Block Kits

Lance Port Plug Module

Level Sensor Module

Prodigy/Encore HD Siphon Tube Module

Purge Manifold and Pneumatics

Purge Valve Assembly − One Lance Configuration

Purge Valve Assembly − Two Lance Configuration

Purge Valve Assembly − Three Lance Configuration

Purge Valve Module Parts

Pneumatic Module Parts

Hopper Platform and Vibrator Parts

Pneumatic Damper Parts

Sieve and Mounting Parts

Replacement Parts for Non-CE/ATEX Sieve 2

Powder Hose and Air Tubing Bulkhead Fittings

Other Service Parts

Options

lb Feed Hopper

Vibrasonic Sieve Screen

Electrical Troubleshooting Procedures

VIBRASONICS/POWER Indicator Troubleshooting

Vibrasonic System Parts

Pneumatic and Electrical Diagrams

Encore

System Setup

System Connections

Spray Gun Connections

Bundling Tubing and Cable

System Air Supply

Power Supply

Entering Configuration Mode

Displays and LEDs

Custom Electrostatic Mode

Classic AFC Mode

Smart Flow Mode Settings

Spray Gun Operation

Daily Operation

Cleaning Flat and Corner Spray Nozzles

Cleaning Conical Nozzles and Deflectors

Changing From Conical to Flat or Corner Spray Nozzle

Shutdown

General Troubleshooting Chart

Spray Gun Power Supply Resistance Test

Gun Cable Continuity Test

Power Supply Replacement

Powder Path Installation

Gun Reassembly

Cable Replacement

Cable Installation

Trigger Switch Replacement

Switch Installation

Controller Repair

Rear Panel Components

Spray Gun Options

Controller Parts

Front Panel and Internal Cabinet Ground Parts List

Rear Panel Parts

Rear Panel Parts List

Manifold Parts

System Components and Parts

Wiring Diagram

declaration of conformity

Part

Electrical Power

Gateway PCA (Printed Circuit Assembly Board Jumper Settings

Software

Hardware Requirements

Gateway Software

Software Version

Addressing Modes

IO Image Table Configuration

Nordson Corporation

IO Image Table − Module Definitions

Sending Messages from the PLC

Unicast Messages from the PLC

Flow % Adjust Message

Reading Data at the PLC − Input Image Table

General System Status

Gateway Heartbeat

Safety Labels

Console and System Hardware and Software

DC Power Supplies

iFlow Digital Flow Module

Special Conditions for Safe Use

Dimensions

Pneumatic Connections

Spray Gun Current Path

ESD Ground Procedures and Equipment

Spray Gun Cable Connections

Manual Spray Gun Controller Addresses

iFlow Module

Spray Gun Control Card Removal/Installation

Adding Spray Guns

iFlow Module Repair

Proportional Valve Replacement

Common Components

Sub-Panel Assembly

Upgrade Kits

Wiring Diagrams and Schematics