Nordson Encore Customer Product Manual
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Nordson Encore Customer Product Manual

Engage external controller
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Encore
Engage External Controller
Customer Product Manual
Part 1615897-01
Issued 05/19
For parts and technical support, call the Industrial Coating
Systems Customer Support Center at (800) 433-9319 or
contact your local Nordson representative.
This document is subject to change without notice.
Check http://emanuals.nordson.com for the latest version.
NORDSON CORPORATION • AMHERST, OHIO • USA

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  • Page 1 For parts and technical support, call the Industrial Coating Systems Customer Support Center at (800) 433-9319 or contact your local Nordson representative. This document is subject to change without notice. Check http://emanuals.nordson.com for the latest version. NORDSON CORPORATION • AMHERST, OHIO • USA...
  • Page 2 Contact Us Notice This is a Nordson Corporation publication which is protected by copyright. Nordson Corporation welcomes requests for information, comments, and Original copyright date 2019. No part of this document may be inquiries about its products. General information about Nordson can be...
  • Page 3 Change Record Change Record Revision Date Change 05/19 New Release. Part 1615897-01 E 2019 Nordson Corporation...
  • Page 4 Change Record Part 1615897-01 E 2019 Nordson Corporation...

  • Page 5: Table Of Contents

    ....... . Encore Engage Gateway ......
  • Page 6 ......... . . Encore Engage Gateway .

  • Page 7: Safety

    Regulations and Approvals 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.

  • Page 8: Personal Safety

    Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation. Use only replacement parts that are designed for use with original equipment. Contact your Nordson representative for parts information and advice. Part 1615897-01 E 2019 Nordson Corporation...

  • Page 9: Grounding

    Disconnect and lock out electrical power. Close pneumatic shutoff valves and relieve pressures. Identify the reason for the malfunction and correct it before restarting the equipment. Disposal Dispose of equipment and materials used in operation and servicing according to local codes. Part 1615897-01 E 2019 Nordson Corporation...

  • Page 10: Safety Labels

    The safety labels are provided to help operate and maintain the console safely. See Figure 1-1 for the location of the safety labels. Item Description WARNING: Disconnect power before servicing. Figure 1-1 Safety Labels Part 1615897-01 E 2019 Nordson Corporation...

  • Page 11: Description

    Engage external controller provides pneumatic support for powder spray gun pumps, and electrostatic support for powder spray guns. The controller uses the Encore Engage Gateway, which provides a network for communication between a main PLC controller and pumps and spray guns.

  • Page 12: Console And System Hardware And Software

    Up to 8 iFlow modules for HDLV configurations Encore Engage Gateway The Encore Engage Gateway is required to provide a communication network between the system’s main PLC controller and the system’s spray guns and pumps. The Gateway must be ordered separately, and is...
  • Page 13 1. Spray gun receptacle panel 4. Fuse 7. Main air 2. Spray gun cards, card cage, and 5. Relay 8. Regulator backplane 6. Slot 9 for Gateway 9. iFlow modules 3. 24 Vdc power supply Part 1615897-01 E 2019 Nordson Corporation...

  • Page 14: Dc Power Supplies

    Dual Spray Gun Cards Each dual spray gun card in the card cage provides electrostatic controls for two Encore automatic powder spray guns. The cards provide a 0−20 Vac (peak) signal to drive the electrostatic power supplies inside the spray guns.

  • Page 15: Iflow Digital Flow Module

    The solenoids can be set to turn on and off as the guns are triggered or to provide a continuous flow. Communication between the iFlow modules and the PCA Gateway is through the internal Nordson CAN network. Part 1615897-01 E 2019 Nordson Corporation...

  • Page 16: Specifications

    Maximum Water Vapor in Air Supply: 0.48 grains/ft Moist or contaminated air can cause the HDLV pumps to malfunction; the powder to cake in the reclaim system, or cause clogging in the feed tubing or spray gun powder paths. Part 1615897-01 E 2019 Nordson Corporation...

  • Page 17: Special Conditions For Safe Use

    Description Special Conditions for Safe Use The Encore Engage Auxiliary Unit is only for use in non-explosive atmospheres. The Encore Engage Auxiliary Unit shall be used with the manufacturer’s applicators that are certified under FM11ATEX0056X, FM13ATEX0006X or FM14ATEX0051X and for manual applicators shall be used with the kit including the manual interface unit certified under FM18ATEX0058X.
  • Page 18 Description Approvals (contd) Figure 2-5 Label for FM Approval Part 1615897-01 E 2019 Nordson Corporation...

  • Page 19: Dimensions

    (25 in.) (24 in.) 1807.5 mm (71 in.) 392.0 mm (15 in.) 6X ø 10.0 196.0 mm MOUNTING HOLES (8 in.) 550.0 mm R618 mm (24 in.) (22 in.) DOOR OPENING Figure 2-6 Dimensions Part 1615897-01 E 2019 Nordson Corporation...
  • Page 20 2-10 Description Part 1615897-01 E 2019 Nordson Corporation...

  • Page 21: Installation

    Therefore, this section provides only basic installation information. Detailed information is contained in the system wiring diagrams, plan views, and other documentation furnished by Nordson application engineering. NOTE: The controller must be installed outside the zone.

  • Page 22: System Connections

    12 Automatic and 4 Manual Spray Gun System Automatic Automatic Automatic Automatic Automatic Automatic Manual Manual +24V@8A +24V@27A Digital I/O +24V@4A AC Power Alarm Relay A− Figure 3-1 12 Automatic and 4 Manual Spray Gun System Part 1615897-01 E 2019 Nordson Corporation...

  • Page 23: Electrical Connections

    AC Power Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î 10018633 Figure 3-2 Back Electrical Connections (Cover Removed) Part 1615897-01 E 2019 Nordson Corporation...

  • Page 24: Pneumatic Connections

    Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î 10018633 Figure 3-3 Back Pneumatic Connections (Cover Removed) Part 1615897-01 E 2019 Nordson Corporation...

  • Page 25: Grounding

    Electrostatic discharges occur at very high frequencies, around 100 MHz. An ordinary ground conductor does not conduct such high frequencies well enough to prevent damage to electronic components. Special flat-braided cables are provided with Nordson powder coating equipment to protect against ESD. Part 1615897-01...

  • Page 26: Spray Gun Current Path

    (spray gun driver board and power supply). Spray Gun Current Path Ions Ground Braid Figure 3-4 Electrostatic Current Path Part 1615897-01 E 2019 Nordson Corporation...

  • Page 27: Esd Ground Procedures And Equipment

    ESD Grounding Procedures and Equipment Always use the special flat-braided copper ESD ground cables furnished with all Nordson spray gun controllers to ground them. The ESD ground cables should always be attached to the booth base, not to a panel, enclosure, or other component bolted to the base.

  • Page 28: Spray Gun Cable Connections

    Cap the unused cable receptacle with the bulkhead seal, then open the console door and unplug the receptacle harness from the spray gun card. Install the jumper in the card receptacle. Refer to the Parts section for seal and jumper part numbers. Part 1615897-01 E 2019 Nordson Corporation...
  • Page 29 Installation Receptacle #8 Bulkhead Harnesses Seal Jumper Install in #8 Card Receptacle Spray Gun Card Figure 3-6 Seal and Jumper Installation − Example Showing 8-Spray Gun System Using Seven Spray Guns Part 1615897-01 E 2019 Nordson Corporation...

  • Page 30: Manual Spray Gun Controller Addresses

    Note: Configuration for VT manual spray guns is not available on the dual channel iFlow module. Configured for Configured for Manual Spray Gun Guns 1 and 2 PD21348 Figure 3-7 iFlow Module Address Set for Manual Spray Guns 1 and 2 Part 1615897-01 E 2019 Nordson Corporation...

  • Page 31: Troubleshooting

    Follow the safety instructions in this document and all other related documentation. NOTE: If the troubleshooting procedures in this section do not solve your problem, contact the Nordson Industrial Coating Systems Customer Support Center at (800) 433−9319 or your local Nordson representative. Spray Gun Card LEDs See Figure 4-1.
  • Page 32 3. Status LED (green) 5. Spray Gun Limit A LED processor) (yellow) 4. Spray Gun Limit B LED (yellow) 2. Fault LED (red) 6. Power LED (green) 7. SW1 (2 position DIP switch for future use) Part 1615897-01 E 2019 Nordson Corporation...

  • Page 33: Iflow Module

    6. Press pushbutton switch SW1 again. The red LED should shut off. 7. Remove the tube plugs from the output ports. 8. Check the gun control panel. With the spray gun off, the customer display should show no air flow. Part 1615897-01 E 2019 Nordson Corporation...
  • Page 34 Troubleshooting Auxiliary Auxiliary Proportional Valves Atomizing Atomizing Flow Flow LED1 +24V 24V COM 5V COM CAN_HI CAN_LO LED2 Transducers Figure 4-2 Dual Pump Control Board Part 1615897-01 E 2019 Nordson Corporation...

  • Page 35: Repair

    Failure to maintain the dust-tight integrity of the enclosures could invalidate agency approvals and create a hazardous condition. Part 1615897-01 E 2019 Nordson Corporation...

  • Page 36: Spray Gun Control Card Removal/Installation

    (6). Push the locking tab up to lock the card into the card cage. Connect the spray gun harness to the two receptacles on the card. Part 1615897-01 E 2019 Nordson Corporation...

  • Page 37: Adding Spray Guns

    11 13 15 Figure 5-3 Spray Gun Control Card Replacement 1. Card cage (slot 1) 3. Spray gun 2 connector 5. Locking tab 2. Gun control card 4. Spray gun 1 connector 6. Backplane Part 1615897-01 E 2019 Nordson Corporation...

  • Page 38: Iflow Module Repair

    9. Install the coil over the valve stem, with the coil wiring pointing toward the circuit board. Secure the coil with the nut. 10. Connect the coil wiring to the circuit board. Part 1615897-01 E 2019 Nordson Corporation...
  • Page 39 Repair Proportional Valve Cleaning Valve Body − Top Valve Body − Bottom Figure 5-4 iFlow Module Cleaning and Repair Part 1615897-01 E 2019 Nordson Corporation...

  • Page 40: Proportional Valve Replacement

    NOTE: If the seals (4) remain in the manifold port, remove them. 2. Check for filter contamination. If filters (5) are discolored, replace filters using service kit 1604436. Replacement instructions are included with kit. Part 1615897-01 E 2019 Nordson Corporation...

  • Page 41: Parts

    Section 6 Parts Introduction To order parts, call the Nordson Industrial Coating Systems Customer Support Center at (800) 433 contact or your local Nordson representative. Controller Configurations See Figure 6-1 and refer to the parts list below for standard configurations. Part...

  • Page 42: Common Components

    PLUG,12 mm, tube 939122 SEAL, conduit fitting, 1/2, blue 148256 PLUG, 10 mm, tubing 1615491 RECEPTACLE ASSEMBLY, HDLV, 12 position, F, ENGAGE 1027256 GASKET, module, digital airflow control 984526 NUT, lock, 1/2 conduit AR: As Required Part 1615897-01 E 2019 Nordson Corporation...

  • Page 43: Sub-Panel Assembly

    KIT, service, dual gun driver PCA, Engage 1615937 POWER SUPPLY, 24 Vdc, 600 W 939953 FUSE, 4A, ceramic, time-delay 1615896 SWITCH, disconnect, 6-pole, DIN rail mount 1615873 FILTER, line, RFI, power, DIN rail mount AR: As Required Part 1615897-01 E 2019 Nordson Corporation...

  • Page 44: Iflow Module

    S KIT FILTER, 20 micron, 0.168 D X 0.125 LG 1027547 S VALVE, proportional, solenoid, sub-base 1099288 S VALVE, solenoid, 3-way, 24 V, 0.35 W, with connector 1039881 KIT, tester, iFlow NOTE A: Contains 6 filters. NS: Not Shown Part 1615897-01 E 2019 Nordson Corporation...

  • Page 45: Upgrade Kits

    Description Note 1616439 KIT, upgrade, dual gun driver, PCA, receptacle, Engage 1616438 KIT, upgrade, iFlow module and receptacle, Engage Encore Engage Gateway The Encore Engage Gateway must be ordered separately. Part Description Note 1616013 KIT, Gateway, Engage, EtherNet/IPt 1616015 KIT, Gateway, Engage, PROFINETr...
  • Page 46 Parts Part 1615897-01 E 2019 Nordson Corporation...

  • Page 47: Wiring Diagrams And Schematics

    Wiring Diagrams and Schematics Section 7 Wiring Diagrams and Schematics Refer to the following foldout wiring diagrams and schematics for the controller. NOTE: Visit Nordson eManuals http://emanuals.nordson.com for a high-resolution view of the wiring diagrams and schematics. Go to Number...
  • Page 48 Wiring Diagrams and Schematics Part 1615897-01 E 2019 Nordson Corporation...
  • Page 50 - Ambient Temperature: +15ºC to +40ºC - Ex tb IIIB T60ºC / Ex II 2 D / 2mJ = (Encore XT and HD Manual Applicators) - Ex tc IIIB T60ºC Dc / Ex II (2) 3 D = (Enhance Manual Interface Controller) - Ex II (2) D = (Engage Controller) –...
  • Page 51 MATERIAL NO. REVISION 10018643 REVISIONS NOTICE THIS DRAWING IS NORDSON PROPERTY,CONTAINS PROPRIETARY INFORMATION AND MUST BE RETURNED UPON REQUEST. DESCRIPTION DO NOT CIRCULATE, REPRODUCE OR DIVULGE TO OTHER PARTIES WITHOUT WRITTEN CONSENT OF NORDSON. ZONE REV. ECO NO. DATE ISSUED 25JAN19...

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