Nordson Encore Enhance Reference guide

EncoreEnhance
Powder Spray Controller
Customer Product Manual
Part 1614575-01
Issued 05/19
NORDSON CORPORATION •AMHERST, OHIO •USA
For parts and technical support, call the Industrial Coating
Systems Customer Support Center at [phone] or
contact your local Nordson representative.
This document is subject to change without notice.
Check http://emanuals.nordson.com for the latest version.

Part 1614575-01 E2019 Nordson Corporation
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 2019. 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, HDLV, iFlow, Select Charge, Nordson and the Nordson logo are
registered trademarks of Nordson Corporation.
All other trademarks are the property of their respective owners.

Change Record i
Part 1614575-01
E2019 Nordson Corporation
Change Record
Revision Date Change
01 05/19 New release.

Change Record
ii
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Table of Contents iii
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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...............................................
Safety Labels 1-4...........................................
Description 2-1.............................................
Introduction 2-1.............................................
Controller Components 2-2.................................
Specifications 3-1..........................................
System Specifications 3-1.................................
Air Quality 3-1...........................................
ATEX, European Union Special Conditions for Safe Use 3-2......
Modular Controls 3-2....................................
Manual Spray Gun Interface 3-2..........................
Encore Enhance Controller Certification Label 3-3.............
Encore Enhance Manual Gun Interface Label 3-3.............
Dimensions for Controller Cabinet 3-4.......................
Setup 4-1..................................................
Encore Enhance System 4-1.................................
Dual Spray Gun Controller Connections 4-1....................
Controller Configuration 4-3..................................
Initial Startup 4-3.........................................
Basic Functions 4-4.......................................
Software Versions 4-5.....................................
Opening the Function Menu and Setting Preferences 4-6......
Functions 4-7............................................
Saving and Restoring Settings −F15 4-11..................
Number of Presets −F17 4-11............................
Triggering −F39 4-12....................................

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Operation 5-1..............................................
Controller Interface 5-2......................................
Interlock Keyswitch 5-4......................................
Presets 5-5.................................................
Creating Presets 5-6......................................
Choosing Presets 5-6.....................................
Changing Presets 5-6.....................................
Electrostatic Settings 5-7....................................
Select ChargerMode 5-7.................................
Custom Mode 5-8........................................
Encore Nano Feedback Control Mode (NFC) 5-9...........
Classic Mode 5-10.........................................
Adjust kV: Classic Mode: Standard (STD) 5-10..............
Adjust mA: Classic Mode: Standard (AFC) 5-11..............
Powder Flow Settings 5-12....................................
HD Powder Flow Settings 5-12..............................
Setting Powder Flow and Atomizing Setpoints 5-13..........
Air Assist and Fast Flow 5-14.............................
VT Powder Flow Settings 5-15..............................
Classic Flow Mode Settings 5-16..........................
Smart Flow Mode 5-16...................................
Color Change Purge (HD Only) 5-20...........................
HD Purge Cycle Instructions 5-20............................
HD Purge Settings 5-21....................................
Help Codes 5-22.............................................
HD System Shutdown 5-23....................................
VT System Shutdown 5-23....................................
Advanced Features 6-1.....................................
Peer-to-Peer (P2P) 6-1......................................
Setup for P2P 6-2........................................
Pairing Interface with iFlow Module 6-4.........................
Pairing New iFlow Module 6-4..............................
Manual iFlow Pairing 6-6..................................
Repair 7-1.................................................
Interface Module Repair 7-1..................................
Disassembly 7-2.........................................
iFlow Module 7-3.........................................
Removal 7-3..........................................
Solenoid Valve Replacement 7-4.........................
Proportional Valve Cleaning 7-4..........................
Proportional Valve Replacement 7-4......................
Filter Replacement 7-6..................................
Troubleshooting 8-1........................................
Help Code Troubleshooting 8-1...............................
Viewing Help Codes 8-1...................................
Clearing Help Codes 8-1..................................
Help Code Troubleshooting Chart 8-2.......................
General Troubleshooting Chart 8-8............................
Re-Zero Procedure 8-13......................................
Flow Air Flow Verification for HD 8-13
..........................

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Maintenance 9-1...........................................
Options 10-1................................................
Adding an Additional Dual Spray Controller 10-1..................
Adding the Top Extension Panel 10-4...........................
Parts 11-1...................................................
Introduction 11-1.............................................
Using the Illustrated Parts List 11-1..........................
Spray Controller Configurations 11-2...........................
Common Components for Spare Parts 11-3.....................
Automatic Spray Controller Module 11-3......................
Manual Spray Controller Module 11-4........................
Manual Gun Interface (MGI) 11-5............................
iFlow Module 11-6.........................................
Power Distribution Module 11-7.............................
Terminal Block Assembly 11-8............................
Blank Panel 11-9..........................................
Top Extension Panel 11-9..................................
System Connections 12-1....................................
Introduction 12-1.............................................
Automatic Spray Gun Controller Electrical Diagram 12-3...........
Manual Spray Gun Controller Wiring Diagram 12-4................
Pump Module Cabinet Diagram 12-5............................

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Safety 1-1
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Section 1
Safety
Introduction
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.
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 Use
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
Susing incompatible materials
Smaking unauthorized modifications
Sremoving or bypassing safety guards or interlocks
Susing incompatible or damaged parts
Susing unapproved auxiliary equipment
Soperating equipment in excess of maximum ratings
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.

Safety
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Personal Safety
To prevent injury, follow these instructions.
SDo not operate or service equipment unless you are qualified.
SDo 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.
SKeep 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.
SRelieve (bleed off) hydraulic and pneumatic pressure before adjusting or
servicing pressurized systems or components. Disconnect, lock out,
and tag switches before servicing electrical equipment.
SObtain and read Safety Data Sheets (SDS) for all materials used.
Follow the manufacturer’s instructions for safe handling and use of
materials, and use recommended personal protection devices.
STo 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.
SDo not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
SProvide adequate ventilation to prevent dangerous concentrations of
volatile materials or vapors. Refer to local codes or your material SDS
for guidance.
SDo not disconnect live electrical circuits while working with flammable
materials. Shut off power at a disconnect switch first to prevent
sparking.
SKnow 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.
SClean, maintain, test, and repair equipment according to the instructions
in your equipment documentation.
SUse only replacement parts that are designed for use with original
equipment. Contact your Nordson representative for parts information
and advice.

Safety 1-3
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Grounding
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.
SAll 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.
SEquipment 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.
SThere 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.
SOperators 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.
SShut off electrostatic power supplies and ground gun electrodes before
making adjustments or cleaning powder spray guns.
SConnect all disconnected equipment, ground cables, and wires after
servicing equipment.
Action in the Event of a Malfunction
If a system or any equipment in a system malfunctions, shut off the system
immediately and perform the following steps:
SDisconnect and lock out electrical power. Close pneumatic shutoff
valves and relieve pressures.
SIdentify 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.

Safety
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Safety Labels
See Figure for location of safety labels and refer to Table for description of
each safety labels. The safety labels are provided to help operate and
maintain equipment safely.
Item Label Description
1. WARNING: Electric hazard
2. WARNING: Fire hazard
3. WARNING: Follow all safety instructions in manual for safe use.
10018185
1
1
1
1
2
3
Figure 1-1 Safety Labels

Description 2-1
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Section 2
Description
Introduction
The EncorerEnhance is an automatic and manual spray gun controller.
The controller includes a power distribution module and can include up to
five spray gun modules. Each spray gun module controls two spray guns.
The controller can be configured for up to a total of ten spray guns:
S4 to 10 automatic spray guns
SUp to 4 manual spray guns (includes remote manual gun interface)
The controller can be paired with Encore HD or venturi style pumps.

Description
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Controller Components
See Figure 2-1 for typical controller components.
1
Front View of Stack Rear View of Stack
2
3
4
5
6
7
8
Figure 2-1 Encore Enhance Spray Gun Controller (shown with 3 automatic gun modules and 1 manual gun module)
1. Automatic spray gun module
2. Manual spray gun module
3. Blank panel (for spacing)
4. Conveyor lockout and bypass
5. Spray module On/Off button
6. Main disconnect
7. Power distribution module
8. Remote manual gun interface
(MGI)

Specifications 3-1
Part 1614575-01
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Section 3
Specifications
System Specifications
Model Input Rating Output Rating
Dual Manual Spray Gun Controller 100-250Vac, 50/60Hz, 90VA max ±19VAC, ±1.0A
Dual Automatic Spray Gun Controller 100-250Vac, 50/60Hz, 90VA max ±19VAC, ±1.0A
Configurable Controller Cabinet 100−250Vac, 50/60Hz, 450VA max ±19VAC, ±1.0A
Environment Factor
Input Air 6.2−7.6 bar (90−110 psi), air supply must be clean
dry air
Maximum Relative Humidity 5−95% non−condensing
Ambient Temperature Rating (Encore System) +15_C to +40°C (+59°F to +104°F)
Air Quality
The air supply must be clean and dry. Use a regenerative desiccant or
refrigerated air dryer capable of producing a 3.4 C (38 F) or lower dew point
at 7 bar (100 psi) and a filter system with pre−filters and coalescent−type
filters capable of removing oil, water, and dirt in the sub−micron range.
Air Quality Factors
Recommended Air Filter Screen Size 5 micron or smaller
Maximum Oil Vapor in Air Supply 0.1 ppm
Maximum Water Vapor in Air Supply 0.48 grains/ft3
Moist or contaminated air can cause the iFlowrmodules to malfunction; the
powder to cake in the feed hopper or clog the pump venturi throats, feed
hoses, and spray gun powder paths; and cause grounding or arcing inside
the spray gun.

Specifications
3-2
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ATEX, European Union Special Conditions for Safe Use
Modular Controls
SThe Encore Enhance Modular Controls shall be installed in a
non−explosive atmosphere.
SThe Encore Enhance Modular Controls shall be used with the
manufacturer’s applicators that are separately certified under
FM11ATEX0056, FM13ATEX0006X, or FM14ATEX00051X.
SThe equipment must be used in accordance with EN 50050−2 for
manual applicators.
Manual Spray Gun Interface
SThe Encore Enhance Manual Spray Gun interface shall be used with the
manufacturer’s applicators that are separately certified under
FM11ATEX0056X or FM14ATEX0051X.
SRefer to the manufacturer’s instructions for guidance on possible static
discharge hazards.
SThe equipment must be used in accordance with EN 50050−2.
CAUTION: Awareness should be taken where cleaning plastic surfaces of
the Encore Enhance Controller. There is a potential for static electricity build
up on these components.

Specifications 3-3
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Encore Enhance Controller Certification Label
1614221−01
Encore Enhance Manual Gun Interface Label
1614799−01

Specifications
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Dimensions for Controller Cabinet
625 mm
(24.6 in)
614 mm
(24.2 in)
2200 mm
(86.61 in)
1807.5 mm
(71.2 in)
698.5 mm
(27.5 in)
1807.5 mm
(71.2 in)
492.5
(15.41)
583.3 mm
(23.0 in)
Figure 3-2 Dual Gun Controller Cabinet Dimensions (shown with optional top cover)

Setup 4-1
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Section 4
Setup
WARNING: Make sure to use qualified personnel to set up the equipment
to prevent electrical shock or personal injury. Make sure that the last
connections made relate to powering up and operation of the equipment.
Encore Enhance System
For Encore Enhance system connections, refer to Wiring Diagrams section
and the Encore Enhance installation guide.
Dual Spray Gun Controller Connections
Use Figure 4-1 as a reference for spray controller connections. Use the
Wiring Diagrams section and the Encore Enhance installation guide for full
installation instructions.

Setup
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1
2
3
4
5
6
7
8
9
11
12
13
14
15
16
17 5
6
7
18
19
21
20
23
24
10 22
Note: Lower panel tilted
to show item 21.
Figure 4-1 System Connections (Auto and Manual Controller Configuration Shown)
1. Spray controller (automatic)
2. Manifold air in
3. Spray gun connections
4. Spray controller (manual)
5. Flow air
6. Atomizing air
7. Electrode air wash
8. Purge air
9. Fluidizing air
10. External signals in
11. I/O connections from power
distribution to controllers
12. Earth ground
13. Air distribution
14. Main air in
15. I/O connections
16. Ground connections
17. AC controller connection
18. CAN connection
19. HD control connection
20. CAN network block
21. Replay terminal block
22. CAN connections for MGI
23. System inputs
24. Main power in connection