Nordson Encore Reference guide

EncorerEngage Gateway
Customer Product Manual
Part 1615959−01
Issued 03/19
NORDSON CORPORATION •AMHERST, OHIO •USA
For parts and technical support, call the
Finishing Customer Support Center at [phone].
This document is subject to change without notice.
Check http://emanuals.nordson.com for the latest version.

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tents
Table of Contents
Safety 1.......................................
Qualified Personnel 1.........................
Intended Use 1..............................
Regulations and Approvals 1..................
Personal Safety 2............................
Fire Safety 2................................
Grounding 3.................................
Action in the Event of a Malfunction 3...........
Disposal 3..................................
Description 4..................................
Installation 5..................................
Installing Gateway into
External/Auxiliary Controller 5.................
Electrical Power 6............................
Fieldbus Connection 6.......................
Gateway PCA (Printed Circuit Assembly)
Board Jumper Settings 7.....................
Software 8....................................
Overview 8..................................
Hardware Requirements 9....................
PCA −PLC Gateway Controller 9............
Anybus Network Interface Module 9.........
Gateway Software 10..........................
Software Version 11........................
Addressing Modes 12.........................
Broadcast Messages 12.....................
Multicast Messages 12......................
Unicast Messages 12.......................
IO Image Table Configuration 13................
IO Image Table −Module Definitions 15.......
Sending Messages from the PLC 24.............
Broadcast Messages from the PLC
(IO Module 1) 26...........................
Multicast Messages from the PLC
(IO Modules 2 and 8) 28....................
Unicast Messages from the PLC 28...........
Flow % Adjust Message 31..................
Reading Data at the PLC −Input Image Table 32..
Gun Monitored Data 32.....................
General System Status 38..................
Gateway Heartbeat 39......................
Parts 40.......................................
Gateway Replacement Parts 40.................
Optional Equipment 40........................
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, Nordson, and the Nordson logo are registered trademarks
of Nordson Corporation.
All other trademarks are the properties of their respective owners.

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Change Record
Revision Date Change
01 03/19 New Release.

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EncorerEngage Gateway
Safety
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 Material Safety Data Sheets (MSDS) 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 MSDS
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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Description
The Gateway is the interface between a main system controller (usually a
PLC) and any of the Engage controllers’ dual channel control modules used
with automatic powder guns.
The Gateway converts standard fieldbus protocol messages and commands
(PROFINETror EtherNet/IPt) from a main system controller into the
proprietary CAN bus messages required to communicate with the pump and
electrostatic modules controlling the automatic spray guns.
See Figure 1. The Gateway is capable of interfacing with up to 32
automatic guns through a single cable to the spray control modules. For a
system with the maximum of 32 spray guns, there are 16 KV nodes and 16
flow nodes connected on a CAN network.
The system is compatible with Encorerand Encore HD automatic guns.
Main System Controller:
PLC, PC, or Robot Controller
Spray Gun
Fieldbus
Wiring
External/Auxiliary Controller
(has no PC touchscreen) Gun Cable
Gateway is in
Slot 9 of card cage
Figure 1 Typical System Diagram

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Installation
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
WARNING: Use dust-tight conduit connectors or strain reliefs to route
cables into all electrical enclosures. Installation must be done according to
code and care must be taken to maintain the dust-tight integrity of the
enclosures.
Installing Gateway into External/Auxiliary Controller
See Figure 2. The Gateway may be inserted into Slot 9 of the card cage.
Additional application installation options include:
SA card cage mounted in a custom-built electrical enclosure.
SA Gateway mounted into a single-slot package, mounted in a custom
electrical enclosure (see page 40).
Card Cage
Sub Panel
Slots 1 −8 reserved for
Dual Gun Driver PCAs
Slot 9 for Gateway
External/Auxiliary Controller
Figure 2 Installing Gateway into External/Auxiliary Controller

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Electrical Power
The Gateway requires 24 Vdc @ 100mA (maximum), which is supplied by
the card cage backplane.
Fieldbus Connection
The fieldbus connection is made directly to the Anybusrsupport board,
which is mounted to the Gateway board. The customer must provide the
appropriate cable for PROFINET or EtherNet/IP networks.

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Gateway PCA (Printed Circuit Assembly) Board Jumper Settings
Verify that all jumpers and switch settings on the Gateway are positioned as
shown in Figure 3.
10013409−02
21 3
JP1
OPEN
OPEN
UP IS
(OFF)
UP IS (OFF)
1234
Default Positions for
DIP Switch SW2:
All “Open” (Shown)
See SW2 Configurations
in Table 17 on Page 39.
Default Positions for
DIP Switch SW1:
All “Open” (Shown)
OPEN
12
1234
Default Position−Not Used
(Jumper placed on Pin 1 Only)
OPEN
Figure 3 Gateway PCA Board Jumper Settings

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Software
Overview
A typical PLC-based powder system utilizing Encore Engage system’s
control modules consists of two basic sub-systems:
Sa PLC which controls the triggering of several guns
Sa CAN network of several intelligent powder flow (either HDLVror
Venturi) and gun KV control modules
Since the Encore Engage system uses separate intelligent modules (or
nodes) for controlling powder flow and gun voltage, the PLC must have the
capability to communicate to two nodes for controlling a single gun.
Furthermore, since each flow or KV control node has two channels for
controlling two guns, each intelligent node must process data and control
information for two separate guns. All of the control nodes are networked
together on a proprietary CAN bus which acts as the communication
channel through which all data and commands to and from the nodes are
sent.
Each Gateway is designed to appear as a single secondary device to the
main PLC, regardless of the number of gun control nodes in the system.
Inside the Gateway, the interface between the two networks is a dual port
memory (DPM) device which is organized such that all data/commands
have a unique address which can be accessed by either network.
NOTE: Another example of a main versus a secondary device would be a
scanner versus an adapter, respectively.
This section describes the specifications required to send commands to the
flow/gun nodes so that they may perform their intended functions. In
particular, the layout of the dual port memory is defined by describing the
function and/or range of values which occupy each address location. The
method for retrieving process data from the secondary nodes, via reading
the dual port memory, is also specified.
Throughout this document, the gun flow and gun voltage control nodes will
be collectively referred to as gun control nodes. For each gun in the
system, there is a KV node which controls that gun’s electrostatics; and
there is a gun flow node to control that gun’s powder flow (HDLV or Venturi).

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Hardware Requirements
Figure 4 describes the hardware components which make up the Gateway
system. The main PLC only sees a single secondary node connected to it.
The Gateway consists of 2 circuit boards:
PCA −PLC Gateway Controller
Scommunicates CAN messages to and from gun control nodes
Sconnects up to maximum of 32 guns per gateway
Sreads and writes to one side of the dual port memory
Anybus Network Interface Module
Sreads and writes data to one side of dual port memory
Sspecific to PLC protocol (PROFINET or EtherNet/IP)
S32 pin header (plug and play −change to any other network
interface without software or configuration changes to the Gateway)
S4 diagnostic LEDs
Saddressable node ID
The Anybus module communicates with the PCA via the address and data
bus and some control signals.
Anybus-S board
with RJ45 Ethernet
Connector
CAN
Interface
Slot 9 Gateway Board
Ethernet
Cable to PLC
CAN
Cable to
Engage
Gun
Control
Nodes
Data
Address
Control
DSP
Edge-Connector to
Card Cage
Backplane
Figure 4 Encore Engage Gateway PCA Diagram

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Gateway Software
Figure 5 describes the software architecture of the Gateway. The shaded
portion represents the software modules specifically developed for the
Gateway. As shown, the Gateway software interfaces to the fieldbus and
CAN bus networks using commercially available hardware, thus realizing a
gateway function.
To Main PLC To Gun Control Nodes
DSP Firmware Module
(which converts dual port memory
data into CAN messages
and vice versa)
PROFINET or
EtherNet/IP
Fieldbus
Interface
Hardware
CPU/
Firmware
Dual Port
Memory
CAN
Interface
Hardware
CAN bus
Fieldbus
S-Module
Figure 5 Gateway Software Modules

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Software Version
The Gateway software version can be determined by observing the flashing
of the Test, COMM, and Fault LEDs when power is applied to the Gateway.
See Figure 6 and Table 1 to determine software version. Each LED relates
to a position in version number represented by X.YZ. Count the number of
flashes to determine the number for that position.
10013409_01
FAULT
COMM
TEST
Figure 6 Location of LEDs on Anybus-S Board for Version Verification
Table 1 LEDs to Version Conversion Chart
LED Label LED Color Position
TEST Green X
COMM Yellow Y
FAULT Red Z

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Addressing Modes
There are three addressing modes which are used for sending and
receiving data/commands from the PLC to the gun control nodes.
Broadcast Messages
See Broadcast Messages from the PLC section on Page 26 for a list of
common broadcast messages.
SSend messages from the PLC to all the gun control nodes
SAssigned top priority
SExamples include Gun Trigger or Lockout
Multicast Messages
See Multicast Messages from the PLC section on Page 28 for more
information on multicast messages.
SSend commands and data from the PLC to a group of gun control nodes
associated with a single gun
SAt this time, multicast addressing only applies to Change Preset
Messages
NOTE: By default, each physical gun in a system also belongs to a
multicast group address (which is equal to the physical gun number). Since
each physical gun is connected to two gun control nodes (one for KV control
and another for Flow control), it is convenient to have the ability to send
certain messages to a given physical gun’s KV node/Flow node pair.
Unicast Messages
See Unicast Messages from the PLC section on Page 28.
SSends commands and data from the PLC to an individual gun control
node (most commonly Set Preset Message)
SSend messages from the gun control nodes to the PLC (includes Gun
Monitor Message and System Status Message)

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IO Image Table Configuration
The PLC programmer will have to configure the main PLC so that its IO
image table matches that of the secondary.
NOTE: For a successful Gateway setup, the PLC programmer should be
familiar with the proprietary Nordson CAN protocol.
The direction of the data (input or output) is from the PLC’s reference point.
The secondary is configured at the factory to have the following 29 IO
modules shown in Table 2.
The details of these IO modules are covered in the following sections.

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Table 2 IO Modules
IO Module No. Module Type Size (Bytes) Descriptions Notes
1 Output 12 Broadcast Message Data A
2 Output 2 Multicast Message Data
3 Output 12 Data Table 5 to KV and Flow (Pump) B
4 Output 1 Gun Bank/Page No. from PLC
5 Output 4 % Flow Trim Adjust B
6 Output 1 Heartbeat from PLC
7 Output 12 General Unicast Message C
8 Output 32 Goto Preset Value (for each gun) D
9 Output 2 Paged Gun General Information
10 Input 12 Paged Gun 1 or 17 Monitored Data/Status E
11 Input 12 Paged Gun 2 or 18 Monitored Data/Status E
12 Input 12 Paged Gun 3 or 19 Monitored Data/Status E
13 Input 12 Paged Gun 4 or 20 Monitored Data/Status E
14 Input 12 Paged Gun 5 or 21 Monitored Data/Status E
15 Input 12 Paged Gun 6 or 22 Monitored Data/Status E
16 Input 12 Paged Gun 7 or 23 Monitored Data/Status E
17 Input 12 Paged Gun 8 or 24 Monitored Data/Status E
18 Input 12 Paged Gun 9 or 25 Monitored Data/Status E
19 Input 12 Paged Gun 10 or 26 Monitored Data/Status E
20 Input 12 Paged Gun 11 or 27 Monitored Data/Status E
21 Input 12 Paged Gun 12 or 28 Monitored Data/Status E
22 Input 12 Paged Gun 13 or 29 Monitored Data/Status E
23 Input 12 Paged Gun 14 or 30 Monitored Data/Status E
24 Input 12 Paged Gun 15 or 31 Monitored Data/Status E
25 Input 12 Paged Gun 16 or 32 Monitored Data/Status E
26 Input 8 Global Status and Fault Info
27 Input 1 Heartbeat from Gateway/Secondaries
28 Input 32 Paged Gun General Information (16 guns) F
29 Input 4 Node Heartbeat Status
NOTE A: The last 3 bytes are never used.
B: The last byte is never used.
C: The last 2 bytes are never used.
D: 1 byte for each of the guns in the system (maximum of 32 guns in a system).
E: Gun number displayed depends on page number value in IO Module 4.
F: Page number is defined by the value of the second byte in IO Module 9.

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IO Image Table −Module Definitions
Each IO module serves a specific purpose in transferring data either to or
from a gun control node. The terms output and input image tables are
referenced from the perspective of the PLC. The following tables describe
the contents of the IO image tables.
Output Image Table
See Table 3.
All of the data contained in the Output Image Table are written by the PLC
to its main IO memory space. A general description of how the data of the
PLC’s output image table flows through the system until it arrives at the gun
control nodes follows. The PLC writes the data to the relative addresses
shown as “Address Offset” (See Table 3) representing locations in the PLC’s
output image table. The fieldbus main sends this data to the Gateway’s
fieldbus secondary where the data is written to the dual port memory by the
PC controller. The relative address of the data in the dual port memory is
identical to the Address Offset used by the PLC. Finally, the data is read
from the dual port memory by the Gateway’s DSP controller and processed
to create a CAN message. This message is sent to the gun control node(s)
on the CAN network.
IO Module 1
When the Gateway detects a new non-zero value in the first byte of IO
Module 1, it will send a broadcast message to all nodes.
The value in the first byte is the broadcast message number. The next 8
bytes of IO Module 1 contain data specific to that message number.
IO Module 2
When the Gateway detects a change in either of the 2 bytes of IO Module 2
(provided the first byte does not equal 0), it will send a multicast message
out to the two nodes (KV and Flow/Pump) associated with the specified gun
number.
IO Module 3
When the gateway detects that a change has taken place in the KV
parameters of IO Module 3, it will send a unicast message out to the
specified gun’s KV node. If the flow parameters in IO Module 3 changed,
then the gateway will send a unicast message to the specified gun’s flow
node. If the gateway detects changes to both KV and flow parameters, it will
send two unicast messages out; one to the specified gun’s KV node and
another to the flow/pump node.
Before setting new KV or flow parameter values, clear the first byte of IO
Module 3 to 0. After new values are written, set the first byte to 1.

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IO Module 4
This IO Module is a single byte value equal to a Page Number, used by the
PLC’s Operator Interface. This value, starting with 0, tells the Gateway
which group of 16 guns is currently being displayed on the PLC. For
example, if this value were equal to 1, then the PLC is currently displaying
guns #17 thru #32.
IO Module 5
This IO Module commands all the flow controls to change its flow rates by a
percentage of the setpoint. A detailed description of this IO Module is
discussed on page 31 under Flow % Adjust Message.
IO Module 6
This IO Module tells the Gateway that the PLC is active and executing its
program. The value in this single byte must change to any new value, at
least, every 5 seconds. It is practical for the PLC to change this value every
second. If the Gateway does not detect any change in this value for 5
seconds, a broadcast message shutting off all the guns will be sent. To
visually verify that the PLC is periodically sending heartbeats, note the
green Status LED on the KV card. The LED will toggle ON and OFF every
time a new value in IO Module 6 is stored.
IO Module 7
This IO Module is used to permit the PLC to send any unicast messages
while IO Module 3 is reserved for the efficient handling of Data Table 5 and
to quickly send these parameters to their respective nodes. IO Module 7 is
provided primarily to send out other Data Tables as unicast messages.