Nordson Encore Installation, Troubleshooting, Repair Download Page 5

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Table of Contents

iii

Part 1618871

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2020 Nordson Corporation

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Overview

2-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Console and System Hardware and Software

2-2

. . . . . . . . . . . . . . .

Main Controller Components

2-2

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Controller Components

2-2

. . . . . . . . . . . . . . . . . . . . . . . .

Remote Controller

2-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Touchscreen Interface

2-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interlock Keyswitch Functions

2-4

. . . . . . . . . . . . . . . . . . . . . . . . . .

DC Power Supplies

2-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dual Spray Gun Cards

2-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spray Gun Pump Control

2-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iFlow

Digital Flow Modules

2-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Internal and External Networks

2-6

. . . . . . . . . . . . . . . . . . . . . . . . .

Conveyor Encoder

2-6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Spray Gun Controller Options

2-6

. . . . . . . . . . . . . . . . . . .

Specifications 2-7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 2-7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump and Spray Gun Pattern Air Quality

2-7

. . . . . . . . . . . . . . . . .

Special Conditions of Use

2-8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Approval Labels

2-8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main and Auxiliary Cabinet Dimensions

2-10

. . . . . . . . . . . . . . . . . .

Remote Controller Touchscreen Interface

2-11

. . . . . . . . . . . . . . . .

Approved Program and User Data Cards/USB

2-12

. . . . . . . . . . . .

Summary of Contents for Encore

Page 1: ...1 Issued 4 20 NORDSON CORPORATION AMHERST OHIO USA 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 ...

Page 2: ... Jackson Street Amherst OH 44001 Notice This is a Nordson Corporation publication which is protected by copyright Original copyright date 2020 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 iFlow Nords...

Page 3: ...Change Record i Part 1618871 01 2020 Nordson Corporation Change Record Revision Date Change 01 4 20 New Release ...

Page 4: ...Change Record ii Part 1618871 01 2020 Nordson Corporation ...

Page 5: ...ponents 2 2 Auxiliary Controller Components 2 2 Remote Controller 2 2 Touchscreen Interface 2 4 Interlock Keyswitch Functions 2 4 DC Power Supplies 2 5 Dual Spray Gun Cards 2 5 Spray Gun Pump Control 2 5 iFlow Digital Flow Modules 2 5 Internal and External Networks 2 6 Conveyor Encoder 2 6 Manual Spray Gun Controller Options 2 6 Specifications 2 7 General 2 7 Pump and Spray Gun Pattern Air Quality...

Page 6: ...s 3 14 Grounding 3 15 PE Protective Earth Grounding 3 15 Electrostatic Grounding 3 15 Spray Gun Current Path 3 16 ESD Ground Procedures and Equipment 3 17 Spray Gun Cable Connections 3 18 Odd Number of Spray Guns 3 18 System Upgrades 3 19 Troubleshooting 4 1 Spray Gun Card LEDs 4 2 Air Flow Re Zero Procedure 4 4 Re Zero Procedure 4 4 Backplane 4 6 Power Supplies 4 8 Flow Node 4 10 Relay Board 4 12...

Page 7: ...uction 6 1 Encore Engage Controllers 6 1 Remote Displays 6 2 Main Controller Components 6 4 Main Controller for Remote Display Components 6 8 Remote Display Components 6 12 Auxiliary Controller Components 6 14 Kits 6 18 iFlow Module 6 18 Dual Manual Spray Gun Interface Kit 6 19 ...

Page 8: ...Table of Contents vi Part 1618871 01 2020 Nordson Corporation ...

Page 9: ...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 using incompatible materials making unauthorized modifications removing or bypassing sa...

Page 10: ...vices To 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 Do not smoke weld grind or use open flames where flammable materials ...

Page 11: ...ounded There 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 Operators must maintain skin to handle contact betw...

Page 12: ...re Engage main system controller auxiliary cabinet and remote controller The safety labels are provided to help operate and maintain the controllers safely See Figure 1 1 for the location of the safety labels Item Description 1 WARNING Disconnect power before servicing 1 10019246 1 10019333 1 10019168 Figure 1 1 Safety Labels ...

Page 13: ...ngage controllers are available Encore Engage Main System Controller Includes touchscreen controls and supports 4 16 powder spray guns Encore Engage System Controller with Remote Interface Controller Supports 4 16 powder spray guns with remote controller for interface controller mobility Encore Engage Auxiliary Controller Provides support for adding an additional 2 16 spray guns Encore Engage Main...

Page 14: ... controls 2 spray guns One 600 W and one 120 W 24 Vdc power supply E stop Flow modules Gateway Auxiliary Controller Components Auxiliary consoles do not include the touchscreen PLC interlock switch relay board or E stop Remote Controller The touchscreen interface is available in a remote controller with mounting hardware and with optional E stop An accessory pedestal is also available The remote c...

Page 15: ... ÎÎ ÎÎ ÎÎ ÎÎÎÎÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎÎÎÎÎ Ï Ï Ï Ï Ì Ì Ì Ì Ì Ì Ì Ñ Ñ Ñ Ñ 1 2 3 4 5 6 7 8 11 12 9 10019246 10 Figure 2 2 Engage Main Console and Pedestal Internal Components 1 Touchscreen interface 2 E stop 3 Power switch 4 Interlock keyswitch 5 Flow modules 6 Gun cable connections 7 Dual spray gun cards card cage and backplane 8 Single 24 V power supply 9 PLC 10 Gateway 11 Relay board 12 24 Vdc power suppl...

Page 16: ...wer NOTE Optional E stop is available for remote controllers 1 2 Figure 2 3 Main Controller and Remote Touchscreen 1 Touchscreen 2 E stop Interlock Keyswitch Functions In the Ready position the spray guns cannot be triggered unless the conveyor is running This prevents powder waste and hazardous operating situations In the Bypass position spray guns can be triggered on and off without running the ...

Page 17: ... 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 ...

Page 18: ...ctive distance parts can be tracked by the Engage system is approximately 431 feet At a 2 1 resolution 1 2 inch per pulse the effective tracking distance is halved to approximately 170 feet The maximum speed of the encoder input is 10 Hz 10 pulses per second This may require a trade off between desired conveyor speed and part tracking resolution the higher the conveyor speed the coarser the tracki...

Page 19: ...Category II Environmental Operating Temperature 15 C to 40 C Operating Humidity 5 95 non condensing Environmental Weight fully populated main controller 345 lb 156 kg Note A Branch circuit breaker 8A Max Pump and Spray Gun Pattern Air Quality 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 ...

Page 20: ...r manual applicators The Encore Engage Main Console with display and the Auxiliary Consoles and Remote Display with Main Console for shall be used within the ambient temperature range of 15 C to 40 C with Encore Automatic or Encore HD Automatic Powder Applicators The Encore Engage Main Console with display and the Auxiliary Consoles and Remote Display with Main Console shall be installed in a non ...

Page 21: ...System Overview 2 9 Part 1618871 01 2020 Nordson Corporation Figure 2 5 Label for CE ATEX Approval On Remote Display Figure 2 6 Label for FM Approval On Main and Auxiliary Cabinets and Remote Display ...

Page 22: ...rdson Corporation Main and Auxiliary Cabinet Dimensions 625 mm 25 in 1807 5 mm 71 in 607 6 mm 24 in 392 mm 15 in 196 mm 8 in R616 DOOR OPENING 6X 10 0 550 mm 22 in 10019246 Figure 2 7 Main and Auxiliary Cabinet Dimensions shown with main cabinet ...

Page 23: ... 2020 Nordson Corporation Remote Controller Touchscreen Interface 704 mm 28 in 564 mm 22 in 414 mm 16 in 256 mm 10 in 287 mm 11 in 10019168 Figure 2 8 Remote Controller Touchscreen Interface Dimensions shown with optional E stop extention ...

Page 24: ...for use with Encore Engage system controllers The following are a list of program and data cards USB and where they are located in the system CFAST Compact Flash Touchscreen interface Micro SD PLC SD eWON Gateway USB Ship with kit NOTE The USB ship with kit is provided with the system for software updates See Maintenance section for how to complete software updates ...

Page 25: ...d requirements The equipment supplied with the system varies depending on the type of installation new upgrade or retrofit and the equipment furnished by the customer 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 Once all hardware is ...

Page 26: ...ctions NOTE For VT systems the P6 connection is not applicable Main Controller Auxiliary Controller Remote Controller Part ID MECP HD Pump Module HD Pump Module Photo Eye Encoder MECP Customer MGI if equipped see note NOTE If system has auxiliary controller MGI connection should be done at P4 location on auxiliary controller If only using a main controller MGI connection should be done at P4 locat...

Page 27: ...ale E net P3 Remote AC Power Source 4A Fused 200VA Maximum P4 Manual Gun Connection CAN 1 CAN 24 V P5 Auxiliary Automatic Cabinet Connection CAN 2 CAN Network Lockout P6 HDLV Pump M12 Conductor Cable 12 Conductor P7 Air Conditioner Power in mini P8 E stop 4 Conductor M12 P9 Enet 3 Remote Screen M12 D Coded Female E net P11 WAN Customer Data M12 D Coded Female E net PC1 Interlock Alarm Optional 1 2...

Page 28: ...1 1 Alarm Relay 250 VAC 1A Max White Black 2 L1 Black 2 Alarm Relay 250 VAC 1A Max Black 3 L2 White 3 N C White P4 1 Drain Bare 4 N C Red 2 24 V Red 5 Lockout 24 VDC 120 230 VAC Orange 3 Common Black 6 Lockout 24 VDC 120 230 VAC Blue 4 CAN H White 7 Chassis Green 5 CAN L Blue P5 1 Drain Bare PC2 1 24 V Brown 2 Aux Lockout Red 2 Encoder Signal White 3 Aux Lockout Black 3 24 V Black 4 CAN H White 4 ...

Page 31: ...matic spray guns and 4 manual spray guns Make sure each cable shield is connected on one end only NOTE Terminating resistors must be installed for dust tight connections Field Connections Flow 1 Flow 2 Flow 3 Flow 4 Flow 5 Flow 6 Flow 7 Flow 8 Flow 9 Flow 10 Flow 11 Flow 12 Flow 13 Flow 14 Manual 1 Manual 2 MGI 4 MGI 3 MGI 2 MGI 1 Backplane Auxiliary T CAN C CAN B CAN A CAN C CAN B CAN A PLC T Bac...

Page 32: ...nnections to P4 or P5 the termination jumper must be installed on JP1 on the flow module in the main controller Table 3 3 CAN Termination Locations System Configuration CAN Termination Locations 32 Automatic Spray Guns includes main and auxiliary cabinets PLC CAN A on Auxiliary Backplane SW1 3 see Figure 3 6 16 Automatic Spray Guns main cabinet only PLC Flow Module 1 see JP1 See Figure 3 5 12 Auto...

Page 33: ...upper backplane if used 1 2 3 SW1 Open Rocker switch Closed top in Open bottom in Slide switch Closed on Open 1 2 3 SW1 Open Auxiliary Backplane Spray Guns 17 32 Main Backplane Spray Guns 1 16 SW1 1 SW1 2 Closed Closed Guns 1 16 Closed Open Guns 17 32 SW1 3 Closed Terminated Open Not Terminated Figure 3 6 System Interconnect Cable Connections Manual Spray Gun Controller Termination Manual spray gu...

Page 34: ... controller functions for basic operation When power is applied to spray controller the function help display screen will quickly scroll through function settings The following controller functions must be set up for basic operation Table 3 4 Controller Basic Function Settings Function Number Function Name Function Values F00 Gun Type 00 Manual 01 Auto 02 Robot 03 Manual with Light on Gun F20 Gun ...

Page 35: ...ion J2 Low Voltage External Connections 8 Common PC Supply 1 Encoder 9 Keyswitch Conveyor Bypass 2 Encoder 10 Keyswitch Lockout 3 Gun Power OK 11 Main Backplane Lockout P2 4 4 Gun Power OK 12 Main Backplane Lockout P2 3 J4 Low Voltage PC Connections 13 AUX Backplane Lockout P2 4 1 Conveyor Interlock Signal 14 AUX Backplane Lockout P2 3 2 No Connection 15 Alarm Input 24 P2 5 3 Encoder 16 Alarm Inpu...

Page 36: ... 12 Vdc source is functioning properly OFF 12 Vdc source not functioning properly Check wiring relay board and power supply 4 24 Vdc Power ON 24 Vdc source is functioning properly OFF 24 Vdc source not functioning properly Check wiring relay board and power supply 5 Conveyor ON Conveyor run signal present or keyswitch is in bypass mode OFF Conyeyor run signal not present Check signal 6 Lockout ON ...

Page 37: ...rdson Corporation 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1 J2 J4 J7 J1 10 10 11121314151617 18 LED1 LED2 LED3 LED4 LED5 LED6 MANUAL ENABLE GUN POWER 12 VDC POWER 24 VDC POWER CONVEYOR LOCKOUT ALARM LED7 Figure 3 7 Relay Board ...

Page 38: ...nsole Power Cable Connections Table 3 5 Console Power Cable Connections Main Console Power Cable Connections Wire Color Pin Function White Black 1 Conveyor run AC common Black 2 Non interlocked AC White 3 Non interlocked AC common Red 4 Interlocked AC Orange 5 Conveyor run AC Blue 6 Interlocked AC common Green 7 Ground Auxiliary Console Power Cable Connections Wire Color Pin Connection Black 2 Int...

Page 39: ...contacts an electrical enclosure or other conductive component The ground conductor wire carries the electrical current directly to ground and short circuits the input voltage until a fuse or circuit breaker interrupts the circuit The sole purpose of the green yellow ground wires bundled with the AC input power cable is to protect personnel from a shock They must be used for PE grounding only Thes...

Page 40: ... the controller through a ground braid and back to the spray gun through the spray gun driver board The current attracted to the booth is returned through the booth ground to the controller and back to the spray gun It is very important to provide a complete circuit for the spray gun current A break in the circuit conductors conveyor booth braided ground cables controller can cause voltage to buil...

Page 41: ...e Flat Braided Ground Cable Grounding Block Kit 1067694 Installation Figure 3 9 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 Keep the cables as short as...

Page 42: ...t even number spray gun For example if there is an 8 spray gun system then number 8 must be the unused spray gun The spray gun card receptacles are labeled on the circuit boards as A odd number spray gun and B even number spray gun Included in the bag with the console keys is a bulkhead seal and jumper The jumper disables the spray gun not detected fault LED on the spray gun card Cap the unused ca...

Page 43: ... 3 19 Part 1618871 01 2020 Nordson Corporation System Upgrades Certain upgrades require updates to the spray gun control card and iFlow module firmware These upgrades should only be done by a Nordson representative ...

Page 44: ...Installation 3 20 Part 1618871 01 2020 Nordson Corporation ...

Page 45: ...hutdown Doing so could corrupt the Engage program and operating system on the program card The troubleshooting in this manual relates to LED and hardware checks for the Engage controller The Engage controller interface software offers operation alert and alarm troubleshooting through the touch screen interface NOTE If the troubleshooting procedures in this section do not solve your problem contact...

Page 46: ... the DS3 LED is not blinking check PLC and check CAN Network Topology Terminations Hardware Fault If DS3 LED is blinking check gun cables plugged into the gun card and plugged into cabinet DS3 Communication Green Normal Blinking Fault OFF Communication Fault Make sure gun card is properly seated in backplane Replace the gun card if other gun cards have power DS4 GUN A Current Limit Yellow Normal O...

Page 47: ... 5 6 1 7 Figure 4 1 Spray Gun Control Card LEDs and Switches 1 DS1 Power green LED 2 DS3 Communication green LED 3 DS2 Fault red LED 4 Reset switch reboots on board processor 5 DS5 GUN B current limit yellow LED 6 DS4 GUN A current limit yellow LED 7 SW1 2 position DIP switch for future use ...

Page 48: ... the control manifolds will result in additional errors Re Zero Procedure See Figure 4 2 For each pump board that is being re zeroed 1 Disconnect the atomizing and flow air tubing from all four of the 8 mm output ports and plug the ports with tube plugs 2 Record the board number and address settings of SW4 for each pump board 3 Set each address switch to zero 4 Press the pushbutton switch SW1 to r...

Page 49: ...Troubleshooting 4 5 Part 1618871 01 2020 Nordson Corporation SW1 SW2 SW3 SW4 Figure 4 2 Dual Pump Control Board ...

Page 50: ... are in place Remove all gun cards If 12 V LED turns ON replace one gun card at a time 12V Power Green Normal ON Fault OFF 24V Power Green Normal ON Fault OFF Check 24 V on P4 24 LED ON Check power supply PS1 DC OK green LED ON Check power supply PS1 AC OK green LED ON LED OFF refer to PS1 in troubleshooting section Power Supplies on page 4 8 5V Power Green Normal ON Fault OFF Check 24 V on P4 24 ...

Page 51: ...Troubleshooting 4 7 Part 1618871 01 2020 Nordson Corporation 10017280 12V 12V 24V 5V Figure 4 3 Location of Backplane LEDs ...

Page 52: ...age 4 6 Remove connector P4 from backplane If DC OK LED remains OFF replace PS1 PS2 120 W 24 Vdc DC OK Power Green Normal ON Fault OFF Check input power to PS2 black and white wire 100 250 Vac 50 60 Hz Check fuse L1B and L2B Check disconnect switch Check input power to controller L1B black and L2B white 100V 250 Vac 50 60 Hz Check output voltage on PS2 red and black wire 23 5 V to 24 5 Vdc Remove ...

Page 53: ...Troubleshooting 4 9 Part 1618871 01 2020 Nordson Corporation 1615937 1609757 600 W 24 Vdc Power Supply 120 W 24 Vdc Power Supply AC OK DC OK DC OK Figure 4 4 Location of LEDs on Power Supplies ...

Page 54: ...Power Supplies troubleshooting on page 4 8 If LED1 OFF only on singlet flow node check for shorted valve wiring LED2 5 V Power Green Normal ON Fault OFF If LED2 is OFF and LED1 is ON either defective LED or replace flow module DS1 Communication Green Normal ON Fault OFF Check CAN network terminations are correct Measure 60 Ω Check for PLC fault Check flow node cabling Check manual gun connections ...

Page 55: ...Troubleshooting 4 11 Part 1618871 01 2020 Nordson Corporation LED2 DS1 DS2 LED1 10017279 10018617 Figure 4 5 Location of LEDs on Flow Node ...

Page 56: ...ck PS1 LED3 12 V Green Normal ON Fault OFF LED4 24 V Green Normal ON Fault OFF Check power on J7 5 and J7 8 Should be 23 5 24 5 Vdc Check PS2 LED5 Conveyor Green Normal ON Fault OFF Check external wiring to PC1 DC AC signal 24V 230 Vac or Vdc Check J7 9 voltage should change with conveyor signal 0 24 V Check keyswitch wiring Check keyswitch contacts are assembled correctly LED6 Lockout Green Norma...

Page 57: ...Troubleshooting 4 13 Part 1618871 01 2020 Nordson Corporation 10012054 Figure 4 6 Location of LEDs on Relay Board ...

Page 58: ...ror in runtime Flash error Checksum error SSL connection inspect log file ON ON PLC runtime started and has error PRG OFF OFF No application found on device Program needs to be reloaded OFF ON Application running Flashing Communication green flashing ON Flashing Application has stopped Program error OFF Flashing Application is stopping SD OFF No micro SD card found Replace Micro SD card ON Micro S...

Page 59: ...ashing Warning Check CAN network topology terminations 60 W Check CAN wiring X6 24 V OFF Check voltage to X6 should be 23 5 to 24 5 Vdc Check PS2 ON 24 Vdc found Status Speed ETH0 2 OFF OFF No active connection ETH0 check connection from PLC to eWON Check eWON power ETH1 no connection ETH2 check for remote HMI connection P2 Check remote HMI power P3 Check remote HMI IP address OFF ON Active connec...

Page 60: ...yor is running Check for power on UL Check relay board Blinking Encoder signal running I Q2 Conveyor OFF Conveyor running ON Conveyor not running Check for power on UL Check relay board I Q3 Booth ON OFF Booth OFF Check for power on UL Check relay board ON Booth ON I Q4 Lockout OFF System locked out Check power on UL Check relay board ON System ready POW OFF No power on X6 Check for 24 V on X6 Che...

Page 61: ...ing 4 17 Part 1618871 01 2020 Nordson Corporation 1618666 SD U1 X1 X2 USB PLC PRG SD ETH2 ETH1 ETH0 Q1 Q2 Q3 Q4 UL X3 RS485 X4 CAN1 X5 CAN2 X6 24 VDC X1 X2 X3 X4 X5 X6 Ethernet Activity Figure 4 7 PLC LED Locations ...

Page 62: ...gital IN 2 Green Normal ON Fault OFF DO Digital OUT Green Normal ON Fault OFF T2M Talk2M Green Normal ON Fault OFF Check WAN connection Check eWON configuration BI1 Button Input Green Normal ON reset button being pressed Fault OFF Table 4 8 Ethernet Ports LED Description LED Color LED State Correction 1 HMI Rectangle Green LAN Orange WAN Normal ON Fault Green OFF Check HMI power Check HMI IP addre...

Page 63: ...eck Ethernet Connection P9 Check part ID Check dual axis Square Green Normal ON Link OK Blinking Ethernet Traffic Fault OFF 4 WAN Rectangle Green LAN Orange WAN Normal ON Fault Green OFF Check WAN connection Green Normal ON Link OK Blinking Ethernet Traffic Fault OFF 1618667 LED Panel Ethernet Ports Reset Button BI1 Main Connector SD Card Slot Figure 4 8 eWON LEDs and Components ...

Page 64: ...Troubleshooting 4 20 Part 1618871 01 2020 Nordson Corporation ...

Page 65: ... Engage console Unless power must be on to test circuits always shut off and lock out power before opening the console to make repairs All repairs should be made by a qualified electrician Failure to observe this warning could result in personal injury or death WARNING Whenever replacing a component that interfaces with the exterior of the enclosures such as an iFlow digital flow module make sure ...

Page 66: ...e is the odd spray gun number the top receptacle is the even spray gun number To remove a card disconnect the spray gun harness connectors 3 and 4 pull down the locking tab 5 then pull the card out of the card cage To install a new card slide the card into the slots in the card cage and seat the card s finger board firmly into the connector slot on the backplane 6 Push the locking tab up to lock t...

Page 67: ...ed fault LED on the card will light and a fault message will appear on the Alarm screen To reset the fault LED open the Alarm screen and touch the Clear All Faults button 6 1 2 3 4 5 2 4 6 8 10 12 14 16 1 3 5 7 9 11 13 15 Spray Gun Connector Configuration on Card 17 19 21 23 25 27 29 31 18 20 22 24 26 28 30 32 Figure 5 9 Spray Gun Control Card Replacement 1 Card cage slot 1 2 Gun control card 3 Sp...

Page 68: ...t and locate PLC 2 Disconnect any Ethernet connections connectors X1 X6 and remove the micro SD card Retain micro SD card for installation into new PLC 3 Pull up on the PLC clips to release PLC from DIN rail 4 Install new PLC onto the DIN rail 5 Install retained micro SD card 6 Remove the factory installed connectors provided on the new PLC to allow use of existing connectors 7 Install connectors ...

Page 69: ...em on the program card NOTE Gaskets are glued to the cabinet and remote display case around the opening Do not damage or remove these gaskets as that will destroy the dust tight integrity of the enclosure and void agency approvals 1 Open main cabinet door or the remote display case 2 See Figure 5 11 Note which IP address is checked on the IPS label 1 on back of the current touchscreen for later us...

Page 70: ... door or remote display case 7 Place the new touchscreen through front opening of door or remote display case 8 Support the touchscreen in the opening while installing brackets and allen screws Torque allen screws to 5 5 6 0 in lb 0 6 0 7 N m 9 Reconnect ground Ethernet and power harness connections 10 Mark the matching IP address noted earlier on the IP label shown in Figure 5 11 of the new touch...

Page 71: ...Repair 5 7 Part 1618871 01 2020 Nordson Corporation 5 7 6 Remote Display Cabinet Door 5 Figure 5 12 Replacing Touchscreen 5 Touch screen 6 Allen screw 7 Bracket ...

Page 72: ...he two long screws 9 to remove the proportional valve from the manifold CAUTION The valve parts are very small be careful not to lose any Do not mix the springs from one valve with those from another The valves are calibrated for different springs 3 Remove the two short screws 10 then remove the valve stem 13 from the valve body 16 4 Remove the valve cartridge 15 and spring 14 from the stem 5 Clea...

Page 73: ...rt 1618871 01 2020 Nordson Corporation 1 8 9 7 11 11 13 14 15 16 17 10 18 19 9 10 Valve Body Bottom Valve Body Top Proportional Valve Cleaning 2 3 4 5 6 7 12 17 18 15 14 Figure 5 13 iFlow Module Cleaning and Repair ...

Page 74: ...ement See Figure 5 13 To remove the gun air solenoid valves 7 remove the two screws in the valve body and lift the valve off the manifold Make sure the O rings furnished with the new valve are in place before installing the new valve on the manifold Filter Replacement See Figure 5 13 1 Remove the screws 1 and washers 2 securing the circuit board 3 to the manifold 6 then remove the circuit board fr...

Page 75: ...troller with Air Conditioner Figure 6 1 Encore Engage Controllers Controller Type Spray Guns Per Controller 2 4 6 8 10 12 14 16 Main Controller 1617972 1617973 1617974 1617975 1617976 1617977 1617978 Main Controller for Remote Display 1617986 1617987 1617988 1617989 1617990 1617991 1617992 Auxiliary Controller 1618801 1617979 1617980 1617981 1617982 1617983 1617984 1617985 Main Controller with Air...

Page 76: ...igure 6 2 and the following parts list Remote Display Pedestal for Remote Display Remote Display with E stop Figure 6 2 Encore Engage Remote Displays Part Description Note 1618033 KIT remote display 1618034 KIT remote display with E stop 1618035 KIT pedestal remote display ...

Page 77: ...Parts 6 3 Part 1618871 01 2020 Nordson Corporation This page intentionally left blank ...

Page 78: ...tion Main Controller Components See Figure 6 3 and the following parts list DSP_10019246 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 14 16 18 17 19 20 21 22 23 24 25 Figure 6 3 Main Controller Components 1 of 2 shown with 16 automatic spray gun controller ...

Page 79: ...pipe HYD X 1 2 steel zinc 1 12 972092 CONNECTOR male elbow 10 mm T x UNI 1 13 1615958 KIT service dual gun driver PCA Engage 1 14 1615873 FILTER line RFI power DIN rail mount 1 15 1615896 SWITCH disconnect 6 pole DIN rail mount 1 16 1618136 FUSE 8A ceramic time delay 5 x 20 1 17 1615937 POWER SUPPLY 24 Vdc 600 W 1 18 1603591 KIT PCA relay board iControl 2 1 19 1618667 SWITCH LAN WAN gateway progra...

Page 80: ...Main Controller Components contd See Figure 6 4 and the following parts list DSP_10019246 26 27 28 29 30 6 30 27 28 28 31 28 27 32 26 33 34 35 37 28 27 36 37 38 39 Figure 6 4 Main Controller Components 2 of 2 shown with 16 automatic spray gun controller ...

Page 81: ...0 RECEPTACLE shielded 8 position S gun 0 4 M 1 33 1603102 CORD SET mini fast 7 COND 90 degree 10 M 1 34 240976 CLAMP ground with wire 1 35 246458 JUMPER ground 4 in 1 36 1617805 RECEPTACLE ASSEMBLY AC power remote display Engage 1 37 1617819 RECEPTACLE ASSEMBLY Ethernet 0 5 M WAN Engage 1 38 1618009 RECEPTACLE ASSEMBLY Etherenet 0 5 M Ethernet 2 Engage 1 39 1618010 RECEPTACLE ASSEMBLY Ethernet 0 5...

Page 82: ...ller for Remote Display Components See Figure 6 5 and the following parts list DSP_10019334 1 2 3 4 5 6 7 8 9 10 11 12 13 14 13 15 17 16 18 19 20 21 22 23 Figure 6 5 Main Controller for Remote Display Components 1 of 2 shown with 16 automatic spray gun controller ...

Page 83: ...ipe HYD X 1 2 steel zinc 1 11 972092 CONNECTOR male elbow 10 mm T x UNI 1 12 1615958 KIT service dual gun driver PCA Engage 1 13 1615873 FILTER line RFI power DIN rail mount 1 14 1615896 SWITCH disconnect 6 pole DIN rail mount 1 15 1618136 FUSE 8A ceramic time delay 5 x 20 1 16 1615937 POWER SUPPLY 24 Vdc 600 W 1 17 1603591 KIT PCA relay board iControl 2 1 18 1618667 SWITCH LAN WAN gateway program...

Page 84: ... Remote Display Components contd See Figure 6 6 and the following parts list DSP_10019334 24 25 26 27 28 5 28 25 26 26 29 26 25 30 24 31 32 33 37 26 25 34 35 36 37 Figure 6 6 Main Controller for Remote Display Components 2 of 2 shown with 16 automatic spray gun controller ...

Page 85: ...0 RECEPTACLE shielded 8 position S gun 0 4 M 1 31 1603102 CORD SET mini fast 7 COND 90 degree 10 M 1 32 240976 CLAMP ground with wire 1 33 246458 JUMPER ground 4 in 1 34 1617805 RECEPTACLE ASSEMBLY AC power remote display Engage 1 35 1617819 RECEPTACLE ASSEMBLY Ethernet 0 5 M WAN Engage 1 36 1618009 RECEPTACLE ASSEMBLY Etherenet 0 5 M Ethernet 2 Engage 1 37 1618010 RECEPTACLE ASSEMBLY Ethernet 0 5...

Page 86: ...Parts 6 12 Part 1618871 01 2020 Nordson Corporation Remote Display Components See Figure 6 7 and the following parts list DSP_10019168 1 2 3 4 5 Figure 6 7 Remote Display Components ...

Page 87: ...Quantity Note 1 1617771 SWITCH emergency stop ATEX 1 A 2 1618448 GASKET foam conductive x1 2 x 18 1 2 in 1 3 1107695 POWER SUPPLY 24 Vdc 60 W 1 4 334805 FILTER line RFI power 10 A 1 5 1618656 HMI programmed Encore Engage 1 NOTE A Only applicable for remote display with E stop ...

Page 88: ...n Corporation Auxiliary Controller Components See Figure 6 8 and the following parts list DSP_10019333 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Figure 6 8 Auxiliary Controller Components 1 of 2 shown with 16 automatic spray gun controller ...

Page 89: ...ube 1 7 1033878 REGULATOR rolling diaphragm 0 120 NPT 1 8 183418 PLUG 12 mm tube 1 9 1604794 CONNECTOR male 12 mm T x RPT 1 10 973399 BUSHING pipe HYD X 1 2 steel zinc 1 11 972092 CONNECTOR male elbow 10 mm T x UNI 1 12 1615958 KIT service dual gun driver PCA Engage 1 13 1618136 FUSE 8A ceramic time delay 5 x 20 1 14 1615873 FILTER line RFI power DIN rail mount 1 15 1615896 SWITCH disconnect 6 pol...

Page 90: ...ation Auxiliary Controller Components contd See Figure 6 9 and the following parts list DSP_10019333 20 21 22 23 24 6 24 21 22 22 25 22 21 26 20 27 28 29 Figure 6 9 Auxiliary Controller Components 2 of 2 shown with 16 automatic spray gun controller ...

Page 91: ...TOR male elbow 16 mm T x RPT with seal 1 24 1005068 UNION F bulkhead 10 mm T x RPT 1 25 1615491 RECEPTACLE ASSEMBLY HDLV 12 position F Engage 1 26 1615490 RECEPTACLE shielded 8 position S gun 0 4 M 1 27 1616083 CORD SET POWER 3 pole female 14 AWG PVC 6 M 1 28 240976 CLAMP ground with wire 1 29 246458 JUMPER ground 4 in 1 NS 900740 TUBING polyurethane 10 6 5 7 mm AR NS 226690 TUBING polyurethane 12...

Page 92: ...IT service iFlow module Engage 1 1 1033171 CONNECTOR orifice 4 mm x R1 8 diameter 0 4 mm 2 2 1030873 VALVE check M8T x R 1 8 M input 4 3 1099281 VALVE solenoid 3 port 24 V 0 35 W 2 4 1027547 VALVE proportional solenoid sub base 4 5 1604437 KIT FILTER 20 micron 0 168 DIA x 125 LG 1 6 1604436 SERVICE KIT filter 20 micron with tool 1 7 972125 CONNECTOR male elbow 10 mm T x UNI 2 ...

Page 93: ...core 2 NS 1046746 TEE DeviceNet cable 5 pin male female female 3 NS 1046749 RESISTOR teminator device mini W 1 NS 1080718 CABLE interface controller 10 ft 3 NS 1046707 CABLE DeviceNet trunk 5 pin mini 300 V 12 M 1 1 KIT Engage manual gun interface quad Encore HD 1 2 1614566 CONTROL UNIT interface Encore Enhance packaged 4 3 1082739 BRACKET rail mount controller interface Encore 4 NS 1046746 TEE De...

Page 94: ...Parts 6 20 Part 1618871 01 2020 Nordson Corporation ...

Page 95: ...ectives standards norms described above Type of Protection 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 Controllers and Remote Display Located in Unclassified Location Zone Ex II 2 D 2mJ Encore Auto Applicator Certificates FM14ATEX0051X Encore XT and HD Manual...

Page 96: ...ULTIPLIER CABLES 1097537 CABLE AUTO ENCORE 8M 1097539 CABLE AUTO ENCORE 12M 1097540 CABLE AUTO ENCORE 16M 1601344 CABLE EXTENSION ENCORE AUTO 4M THE APPLICATORS AND CABLES ARE SUITABLE FOR CLASS ll DIV 1 GROUP F G HAZARDOUS CLASSIFIED LOCATIONS OR Ex II 2 D EXPLOSIVE ATMOSPHERES GUNS 1603160 APPLICATOR ASSY MANUAL ENCORE HD CABLES 1600745 CABLE ASSY ENCORE XT HD 6M 1085168 CABLE EXTENSION 6 CONDUC...

Page 97: ... ll DIV 1 GROUP F G HAZARDOUS CLASSIFIED LOCATIONS OR Ex II 2 D EXPLOSIVE ATMOSPHERES GUNS 1097489 APPLICATOR BAR MT AUTO ENCORE 1099824 APPLICATOR TUBE MT AUTO ENCORE 5FT 1097500 APPLICATOR TUBE MT AUTO ENCORE 6FT 1606986 APPLICATOR TUBE MT AUTO ENCORE 5FT PVC 1606969 APPLICATOR BAR MT ENCORE HD AUTO 1606970 APPLICATOR TUBE MT AUTO 5FT ENCORE HD 1606985 APPLICATOR TUBE MT AUTO 5FT PVC ENCORE HD 1...

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