4
Troubleshooting
Refer to your system manual for more troubleshooting procedures, resistance checks, and continuity checks.
Problem Possible Cause Corrective Action
1. Gun not spraying powder,
Trigger LED blinking
Gun triggered while controller powering
up or waking up, or shorted trigger
switch or cable
Release the spray trigger. Press the
Disable/Enable button to put the controller
to sleep, then press it again to wake it up.
Check the cable and trigger switch.
2. Powder not charging,
kV/mA display blinking
Gun is shorted Check gun cable and power supply. Refer
to your system manual.
3. Uneven pattern, unsteady
or inadequate powder
flow
Blockage in spray gun, powder feed
hose, or pump
Purge the gun. Check the feed hose and
pump.
Nozzle, deflector, or electrode
assembly worn
Remove, clean, and replace as necessary.
Low pump air pressure Increase pump air setpoints.
Low fluidizing air pressure Increase air pressure.
Damp powder Check powder supply.
4. Voids in powder pattern
Worn nozzle or deflector Remove and replace if necessary.
Plugged electrode assembly or powder
path in gun
Remove and clean.
5. Low powder flow or
surging
Low supply air pressure Input air must be greater than 4.1 bar (60
psi).
Pump throat worn Check and replace if necessary.
Pickup tube blocked Check and clean if necessary.
Fluidizing air not adjusted correctly Check and adjust.
Powder hose plugged, kinked, or ID too
small for length
Check hose. If longer than 20 ft, use 1/2
in. ID hose.
Regulator on controller manifold
plugged or malfunctioning
Remove tubing at controller and check air
flow. Replace regulator if necessary.
6. Loss of wrap, poor
transfer efficiency
Low electrostatic voltage Increase voltage setpoint.
Poor electrode connection Remove and clean. Check electrode and
gun power supply.
Poorly grounded parts Check part grounds. Resistance to ground
should be less than 1 mΩ.
7. Powder build up on
electrode
Insufficient air wash air Remove air wash connector from rear
panel. Check orifice for blockage and
clean if necessary.
8. No kV output from gun
Damaged gun cable or gun power
supply
Check cable and power supply.
9. No kV and powder output
from gun or no purge air
Malfunctioning trigger switch or cable Check Trigger LED. Check trigger switch
and cable.
10. 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, making sure the ribbon cable
is fully inserted into the J8 connector. See
operator’s manual for more information.
Issued 11/13
Original copyright date 2011. Encore, Nordson, and the Nordson logo are registered trademarks of Nordson Corporation.
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