Nordson Encore Reference guide

EncorerEngage External Controller
Customer Product Manual
Part 1615897-01
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 1615897-01 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, Nordson and the Nordson logo are registered
trademarks of Nordson Corporation.
All other trademarks are the property of their respective owners.

Change Record i
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Change Record
Revision Date Change
01 05/19 New Release.

Change Record
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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.............................................
Console and System Hardware and Software 2-2...............
Controller Components 2-2................................
Encore Engage Gateway 2-2..............................
DC Power Supplies 2-4...................................
Dual Spray Gun Cards 2-4.................................
Spray Gun Pump Control 2-4..............................
iFlow Digital Flow Module 2-5..............................
Specifications 2-6...........................................
General 2-6..............................................
Input Air Quality Requirement 2-6..........................
Special Conditions for Safe Use 2-7.........................
Approvals 2-7............................................
Dimensions 2-9..........................................
Installation 3-1.............................................
Introduction 3-1.............................................
System Connections 3-2.....................................
Connection Diagrams 3-2..................................
12 Automatic and 4 Manual Spray Gun System 3-2.........
Electrical Connections 3-3...............................
Pneumatic Connections 3-4.............................
Grounding 3-5...........................................
PE (Protective Earth) Grounding 3-5......................
Electrostatic Grounding 3-5..............................
Spray Gun Current Path 3-6.............................
ESD Ground Procedures and Equipment 3-7..............
Spray Gun Cable Connections 3-8............................
Odd Number of Spray Guns 3-8............................
Manual Spray Gun Controller Addresses 3-10.................
Troubleshooting 4-1........................................
Spray Gun Card LEDs 4-1...................................
iFlow Module 4-3...........................................
Air Flow Re-Zero Procedure 4-3............................
Re-Zero Procedure 4-3.................................

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Repair 5-1.................................................
Spray Gun Control Card Removal/Installation 5-2...............
Replacing a Spray Gun Control Card 5-2....................
Adding Spray Guns 5-3...................................
iFlow Module Repair 5-4.....................................
Proportional Valve Cleaning 5-4............................
Proportional Valve Replacement 5-6........................
Gun Air Solenoid Valve Replacement 5-6....................
Filter Replacement 5-6....................................
Parts 6-1...................................................
Introduction 6-1.............................................
Controller Configurations 6-1.................................
Common Components 6-2...................................
Sub-Panel Assembly 6-3..................................
iFlow Module 6-4.........................................
Upgrade Kits 6-5...........................................
Encore Engage Gateway 6-5.................................
Wiring Diagrams and Schematics 7-1........................

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.

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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.

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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.

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Safety Labels
Table 1-1 contains the text of the safety labels on the front of the cabinet.
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
1.
WARNING: Disconnect power before servicing.
1
Figure 1-1 Safety Labels

Description 2-1
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Section 2
Description
The EncorerEngage 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. The controller supports either venturi or HD Encore spray guns.
NOTE: Encore Engage Gateway sold separately.
Each controller can support up to 16 automatic spray guns. Up to 4 manual
guns can be substituted for automatic spray guns.
10018633
Figure 2-2 Encore Engage External Controller

Description
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Console and System Hardware and Software
Controller Components
See Figures 2-3. A fully equipped controller controlling 16 spray guns
contains the following hardware:
SBackplanes, 8 dual spray gun control cards, and card cage (1 card
controls 2 spray guns)
SOne 600 watt 24 Vdc power supply
SUp to 8 iFlow modules for HDLVrconfigurations
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
available as PROFINETror EtherNet/IPtprotocols.

Description 2-3
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9
8
7
1
6
5
3
4
2
10018633
Figure 2-3 Controller Components
1. Spray gun receptacle panel
2. Spray gun cards, card cage, and
backplane
3. 24 Vdc power supply
4. Fuse
5. Relay
6. Slot 9 for Gateway
7. Main air
8. Regulator
9. iFlow modules

Description
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DC Power Supplies
One 600-watt 24 Vdc provides 24 Vdc power to the spray gun cards and
flow nodes
NOTE: The relay board converts 24 Vdc to 12 Vdc for the display.
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.
The dual spray gun card also provides process feedback to the operator
interface.
Spray Gun Pump Control
The controller controls the powder pumps and the manual spray gun
controllers control the powder pumps through the CAN network. In the
pump cabinet, one pump control card controls two pumps.
Refer to the pump and pump panel manuals for wiring diagrams, parts lists,
and other information.

Description 2-5
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iFlow Digital Flow Module
The controller controls air flow to the pumps supplying powder to the
automatic spray guns. The flow controls consist of precision regulators and
iFlow digital flow modules.
One regulator supplies air to two iFlow modules. Each module supplies flow
and atomizing air to two powder pumps, plus gun air (electrode wash air) to
two spray guns. Flow and atomizing air is turned on and off when the spray
guns are triggered on and off.
For HD pumps, the iFlow module also includes HDLV valve drivers to
control the HD pumps.
The modules provide closed-loop control of the flow and atomizing air,
constantly sensing the output and adjusting it to maintain air flow at the
preset settings. The regulators provide air at a constant pressure to the
iFlow modules so the closed-loop controls can operate at the calibrated
range. The regulators are set 85−86 psi (5.86−5.93 bar) at the factory—do
not change their settings.
Maximum output per flow module is 27.18 m3/hr (16 scfm). Maximum
output per channel is 6.80 m3/hr (4 scfm).
Two solenoid valves on the iFlow modules control the flow of gun air to the
spray guns. The air flow is regulated by a fixed-orifice restrictor at the
output. 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.

Description
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Specifications
General
See Figures 2-6 for controller dimensions.
Electrical Requirements
Input
(See Note B)
100−250 Vac, 50−60 Hz, 1 Phase, 400VA max.
Conveyor Interlock, Remote Lockout: 120/230 Vac, 50/60 Hz, 1 ∅, 6 mA
Output (to spray gun) ±19V, ±1A (peak)
CAN 1 (manual gun
connection)
24 V, ±10% at 4A Fused
NOTE A: The controller must be interlocked with the fire detection system so that the spray guns are shut
off if a fire is detected inside the spray booth.
NOTE B: Branch circuit breaker 10A Maximum
D I/O
Lockout
(Open=System Lockout)
24 V 5 mA, Contact Closure
Alarm
(Contacts Closed=System
Good
Contact Closure 60 V maximum at 1A
ANSI/ISA S82.02.01
Pollution Degree 2
Installation (Overvoltage) Category II
Environmental
Operating Temperature +15_C to +40_C
Operating Humidity 5−95%, non-condensing
Weight
16 Spray Gun Controller 137 kg (302 lb)
Note B: Branch circuit breaker 10A Max.
Input Air Quality Requirement
Air must be clean and dry. Use a regenerative desiccant or refrigerated air
dryer capable of producing a 3.4 oC (38 oF) or lower dew point at 7 bar
(100 psi) and a filter system with prefilters and coalescent-type filters
capable of removing oil, water, and dirt in the submicron range.
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 HDLV pumps to malfunction; the
powder to cake in the reclaim system, or cause clogging in the feed tubing
or spray gun powder paths.

Description 2-7
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Special Conditions for Safe Use
SThe Encore Engage Auxiliary Unit is only for use in non-explosive
atmospheres.
SThe 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.
SThe equipment must be used in accordance with EN 50177 for
automatic applicators and EN 50050-2 for manual applicators.
CAUTION: Caution should be taken when cleaning plastic surfaces on the
Encore Engage External Controller. There is a potential for static electricity
buildup on these components.
Approvals
Figure 2-4 Label for CE Approval

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Approvals (contd)
Figure 2-5 Label for FM Approval

Description 2-9
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Dimensions
625 mm
1807.5 mm
601.7 mm
R618 mm
DOOR
OPENING
392.0 mm
196.0 mm
550.0 mm
6X ø 10.0
MOUNTING HOLES
(25 in.) (24 in.)
(71 in.)
(15 in.)
(8 in.)
(22 in.)
(24 in.)
Figure 2-6 Dimensions

Description
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