Nordson Encore iControl 2 Guide

EncoreriControlr2
Integrated Control System
Installation, Troubleshooting, Repair
Customer Product Manual
Part 1603638-07
Issued 05/16
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 1603638-07 E2016 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 2013. 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, iControl, 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
Part 1603638-07
E2016 Nordson Corporation
Change Record
Revision Date Change
03 08/14 Updated part number 1603070 to 1605755.
04 09/14 Re-zero procedure revised
05 04/15 Removed part numbers from parts list.
06 11/15 Monitor design improvement
07 05/16 Added clarification to Console Power Cable Connections table. Updated
wiring diagrams.

Change Record
ii
Part 1603638-07 E2016 Nordson Corporation

Table of Contents iii
Part 1603638-07
E2016 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.......................................
System Manuals 2-1........................................
Console and System Hardware and Software 2-2...............
Main Console Components 2-2.............................
Auxiliary Console Components 2-2.........................
Pedestal / Main Components 2-2...........................
Standard System Functions 2-2............................
Operator Interface 2-4....................................
Interlock Keyswitch Functions 2-4........................
DC Power Supplies 2-4...................................
Dual Gun Cards 2-5......................................
iFlow Digital Flow Modules 2-5.............................
Internal and External Networks 2-6.........................
Digital Inputs 2-6.........................................
Conveyor Encoder 2-6..................................
Specifications 2-7...........................................
General 2-7..............................................
Air Quality 2-7...........................................
Special Conditions for Safe Use 2-8.........................
Approval Labels 2-8......................................
Pedestal Dimensions 2-10..................................
Console Dimensions 2-11..................................
Approved Program and User Data Cards 2-12.................

Table of Contents
iv
Part 1603638-07 E2016 Nordson Corporation
Installation 3-1.............................................
Introduction 3-1.............................................
System Connections 3-2.....................................
Connection Diagrams 3-2..................................
Interconnect Cables 3-3...................................
CAN Network Address and Termination Settings 3-4..........
iFlow Module Switch Settings 3-5...........................
Power Connections 3-6......................................
Console Power Cable Connections 3-6......................
Grounding 3-7...........................................
PE (Protective Earth) Grounding 3-7......................
Electrostatic Grounding 3-7..............................
Gun Current Path 3-8...................................
ESD Ground Procedures and Equipment 3-9..............
Encoder, Photoeye, and Scanner Connections 3-9..............
Part ID Cable Connections 3-10..............................
Using Trigger Banks 3-10................................
Switching I/O Inputs to Sourcing 3-11......................
Photoeye Junction Box 3-11................................
Power Requirements 3-11................................
Conveyor Encoder Connections 3-11......................
Photoeye Connections 3-11..............................
Scanner Cable Connections 3-12............................
Discrete Scanner Connections 3-12........................
Analog Scanner Connections 3-13.........................
Customer-Supplied Part ID System Connections 3-13..........
Ethernet Network Connections 3-14............................
Connection Diagram 3-14...................................
MAC Addresses 3-14......................................
Gun Cable Connections 3-15..................................
Odd Number of Guns 3-15..................................
Pneumatic Connections 3-16..................................
Supply Air Requirements 3-16...............................
Gun and Pump Air Connections 3-16.........................
Program and User Data Cards 3-18............................
Touch Screen Calibration 3-19.................................
System Upgrades 3-19.......................................
Optional Air Conditioner Installation and Operation 3-20...........

Table of Contents v
Part 1603638-07
E2016 Nordson Corporation
Troubleshooting 4-1........................................
Error Codes and Alarm Messages 4-1.........................
CAN Network Errors 4-7.....................................
Gun Card Troubleshooting 4-8................................
Gun Card Error Codes and Fault Codes 4-8..................
Gun Card LEDs 4-10.......................................
iFlow Module Troubleshooting 4-12.............................
Re-Zero Procedure 4-12....................................
iFlow Module Error Codes and Fault Codes 4-13..............
Ethernet Network Troubleshooting 4-15.........................
In/Out Positioner Troubleshooting 4-17.........................
In/Out Positioner Error Code Troubleshooting 4-17.............
Other In/Out Positioner Troubleshooting 4-20.................
Reciprocator Troubleshooting 4-24.............................
Reciprocator Error Code Troubleshooting 4-24................
Other Reciprocator Troubleshooting 4-27.....................
Other Fault Messages and Conditions 4-30......................
Photoeye, Encoder, and Interlock Troubleshooting 4-31...........
Touch Screen Troubleshooting 4-32.............................
Touch Screen Calibration 4-32..............................
Normal Calibration 4-32..................................
Problems During Calibration 4-32.........................
Calibration with a Mouse 4-33.............................
No Touch Screen Display 4-33..............................
Touch Screen Failure 4-34..................................
Screens Display, but Touch Function Does Not Work 4-34....
No Display 4-34.........................................
Repair 5-1.................................................
Flow Module Repair 5-2.....................................
Proportional Valve Cleaning 5-2............................
Proportional Valve Replacement 5-4........................
Gun Air Solenoid Valve Replacement 5-4....................
Gun Control Card Removal/Installation 5-4.....................
Replacing a Gun Control Card 5-4..........................
Adding Guns 5-5.........................................
Replacing A Card 5-5.....................................
Ribbon Cable Connections 5-6...............................
Touch Screen Replacement 5-7...............................
Parts 6-1...................................................
Introduction 6-1.............................................
iControl 2 Controllers and Interconnect Cables 6-1..............
Main/Auxiliary Console Parts 6-2..............................
Pedestal Parts 6-8..........................................
IFlow Module Parts 6-10....................................
Options 6-11................................................
Miscellaneous Kits 6-11....................................
Conveyor Encoder 6-11....................................
Photocells and Scanners 6-11...............................
Photocell and Scanner Cables 6-12..........................
Wiring Diagrams and Schematics 7-1........................

Table of Contents
vi
Part 1603638-07 E2016 Nordson Corporation

Safety 1-1
Part 1603638-07
E2016 Nordson Corporation
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
1-2
Part 1603638-07 E2016 Nordson Corporation
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
Part 1603638-07
E2016 Nordson Corporation
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
1-4
Part 1603638-07 E2016 Nordson Corporation
Safety Labels
Table 1-1 contains the text of the safety labels on the front of the iControl
master and auxiliary cabinets and on the rear of the pedestal. The safety
labels are provided to help you operate and maintain your console safely.
See Figure 1-1 for the location of the safety labels.
Item Part Description
1. 1034161
WARNING: Disconnect power before servicing.
1
1
Figure 1-1 Safety Labels

System Overview 2-1
Part 1603638-07
E2016 Nordson Corporation
Section 2
System Overview
System Manuals
This manual covers the iControl 2 system hardware for Encore iControl 2
systems used with Encore automatic spray guns.
iControl 2 manuals are organized as follows:
Operator Interface Manual: Covers configuration, preset setup, and
operation using the iControl 2 software and touch screen.
S1056418
Operator Card: for all versions of the iControl 2 systems.
S1024758
Hardware Manual: Covers installation, troubleshooting, repair, parts and
drawings for this system only.
The Encore iControl 2 systems can consist of a main console (16 guns), a
main console and auxiliary console (32 guns), a pedestal/main console (16
guns) or a pedestal/main and auxiliary consoles (32 guns).
Main−Auxiliary System Pedestal/Main System
Figure 2-2 iControl 2 Consoles and Pedestal

System Overview
2-2
Part 1603638-07 E2016 Nordson Corporation
Console and System Hardware and Software
Main Console Components
See Figures 2-3 and 2-4. A fully equipped main console controlling 16
spray guns contains the following hardware:
SLCD touch-screen display, interlock keyswitch, and power switch.
SComputer (PC)
STwo CompactFlash cards, one for the iControl 2 program and one for
user data
SI/O board and relay board
Sbackplane, card cage, and 8 gun control cards (1 card controls 2 guns)
S400 watt and 120 watt 24Vdc power supplies
S8 iFlowrdigital flow modules (1 flow module supplies 2 guns)
S4 preset precision regulators (one regulator supplies two flow modules)
Auxiliary Console Components
When the system has more than 16 guns, auxiliary consoles are added.
Auxiliary consoles do not include the computer, display, interlock keyswitch,
60 watt power supply, I/O board, or relay board.
Pedestal / Main Components
The operator interface can be located in pedestal instead of the main
console if desired. The pedestal houses the display, computer, interlock
keyswitch, and I/O board, while all other hardware stays in the main
console.
Standard System Functions
Standard iControl 2 system functions control gun triggering, electrostatic
charging, and powder flow and velocity. Up to 255 part recipes (presets)
can be created containing settings for each. In addition to the
console/pedestal hardware, the iControl 2 system also requires external
part ID sensors such as photoeyes or scanners for part identification and
zone detection and a conveyor encoder to track part movement.
In addition, the iControl 2 system also controls in/out positioners and
reciprocators. Recipes can include move settings for these devices.
Positioners move the guns in and out of the booth as parts pass through the
booth. Positioner motion is typically horizontal but for some applications the
positioners move the guns up and down. Reciprocators move the guns up
and down with stroke lengths that vary depending on part size. For both,
travel and motion is dependent on the recipe settings for the part.
Both positioners and reciprocators require analog scanner signals for
accurate part width and height measurement.

System Overview 2-3
Part 1603638-07
E2016 Nordson Corporation
The spray guns can also be mounted on oscillators, which move up and
down with fixed stroke lengths. Oscillators are typically controlled from the
main system control panel.
2
4
3
6
5
8
9
7
1
Pedestal Interior
4
3
5
Figure 2-3 iControl 2 Main Console and Pedestal Internal Components
1. iFlow digital airflow modules
2. Regulators
3. PC
4. Touch screen display
5. I/O board
6. Dual gun cards, card cage, and
backplane
7. Power supply −multiple output
8. Relay board
9. 24Vdc power supply

System Overview
2-4
Part 1603638-07 E2016 Nordson Corporation
Operator Interface
The operator performs all configuration and operation tasks with the touch
screen and iControl 2 software. The software provides the operator a
graphical user interface for system configuration, operation, and
troubleshooting.
1
2
3
Figure 2-4 Main Console and Pedestal Front Panels
1. Interlock keyswitch
2. LCD touch screen
3. Power switch
Note: The operator interface software and operating system should be completely
shut down before turning off console power.
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, you can trigger the guns on and off without running
the conveyor. Use the Bypass position to set up and test spray gun
settings.
In the Lockout position, the guns cannot be triggered and the in/out
positioners and reciprocators cannot be moved. Use this position when
working inside the booth. The lockout can be overridden for the in/out
positioners and reciprocators from their configuration screens.
DC Power Supplies
There are two power supplies in the console, a 400 watt, multiple output
power supply and a 120 watt, 24Vdc power supply. The 400 watt power
supply provides power to the iFlow modules and the dual gun cards. The
120 watt power supply provides 24Vdc power to the PC and relay board.
The relay board converts 24Vdc to 12Vdc for the display.

System Overview 2-5
Part 1603638-07
E2016 Nordson Corporation
Dual Gun Cards
Each dual 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 Encore
spray guns. The dual gun card also provides process feedback to the
operator interface.
iFlow Digital Flow Modules
The iControl 2 system controls air flow to the pumps supplying powder to
the automatic spray guns. The flow controls consist of the 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.
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 5.86 bar (85 psi) at the factory—do not
change their settings.
Maximum output per powder pump is 13.6 m3/hr (8 scfm). Each channel
(flow or atomizing air) has a maximum output of 6.8 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 iControl 2 PC is
through the internal CAN network.
1
5
34
2
6
7
8
34
7
8
Figure 2-5 iFlow Digital Flow Module Components
1. Circuit board
2. Air input fittings
3. Atomizing air orifice
4. Flow air orifice
5. Flow sensor (part of circuit board)
6. Solenoid valves (gun air)
7. Flow air proportional valve
8. Atomizing air proportional
valve

System Overview
2-6
Part 1603638-07 E2016 Nordson Corporation
Internal and External Networks
The iControl 2 system uses both a CAN network for internal
communications and an Ethernet network for external communications.
CAN Network: Handles communications between the gun control cards,
iFlow modules, and the iControl 2 PC. The CAN network is also used to
communicate with the gun control cards and iFlow modules in auxiliary
consoles. If two booths are on the same line, the CAN network can also
communicate with auxiliary consoles controlling the 2nd booth guns.
Ethernet Network: Handles communications between the iControl 2
system, the main electrical control panel, and the Part ID panel(s).
Digital Inputs
The iControl 2 system includes an I/O board that provides optically isolated
digital inputs. Included are:
Seight discrete (digital) inputs for zone detection (gun triggering).
Seight discrete (digital) inputs for part identification (recipe select).
Sone input for a conveyor encoder (encoder A).
Sone input each for trigger bank 0, trigger bank 1, and trigger select.
The above inputs are used to track parts through the powder coating
system, select the desired recipe for the part, and trigger on and off the
appropriate spray guns when the parts reach the desired trigger points.
All the digital inputs are routed through a part ID junction box on the part ID
stand. A 24Vdc power supply in the junction box provides power for the
photoeyes and scanners. A second junction box may be used depending
on the number and type of scanners in the system.
A cable connects the part ID junction box to the iControl 2 main console or
pedestal. The cable plugs into the PD1 connector on the console or
pedestal, then is field-wired to the terminal block in the part ID junction box.
Conveyor Encoder
The encoder can be either mechanical or optical and must have a 50% duty
cycle.
Resolution: At an encoder resolution of one inch to one pulse (1:1), the
effective distance parts can be tracked by the iControl 2 system is
approximately 1333 feet. At a 2:1 resolution (1/2inch per pulse), the
effective tracking distance is halved, to approximately 666 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 tracking
resolution).
NOTE: A internal clock or an external timer may be used instead of an
encoder. Consult with your Nordson representative.

System Overview 2-7
Part 1603638-07
E2016 Nordson Corporation
Specifications
General
See Figures 2-9 and 2-10 for pedestal and console dimensions.
Air Pressures
Input 6.2−7.6 bar (90−110 psi)
Supply air hose 3/4-in. ID minimum
Maximum output per pump 13.6 m3/hr (8 scfm)
Maximum output per channel 6.8 m3/hr (4 scfm) (flow-rate, atomizing)
Gun air (electrode wash) 0.36 m3/hr (0.2 scfm)
Electrical Requirements
Input Unswitched: (PC) 100−230 Vac, 50/60 Hz, 1 ∅, 100 VA max.
Switched: 100−230 Vac, 50−60 Hz, 1 ∅, 250VA max.
Conveyor Interlock, Remote Lockout: 120/230 Vac, 50/60 Hz, 1 ∅, 6 mA
Alarm Relay contact rating: 120/230 Vac, 1 ∅, 6 A
Output (to spray gun) ±19V, ±1A (peak)
Output (to pedestal) +24Vdc, +12Vdc
NOTE: The iControl 2 system 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.
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
Hazardous Location Rating
(See Note)
North America: Class II Division 2, Groups F & G
EU: Zone 22 area.
Note: Only the iControl 2 Pedestal is certified for hazardous locations or zones. The Main and
Auxiliary Consoles must always be located outside the hazardous area or zone.
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
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 iFlow modules 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.

System Overview
2-8
Part 1603638-07 E2016 Nordson Corporation
Special Conditions for Safe Use
The Encore Automatic Powder Spray Applicators shall only be used with the
associated Encore iControl 2 integrated controllers over the ambient
temperature range of + 15 _C to + 40 _C.
Only the iControl 2 Pedestal is certified for hazardous locations or
zones. The Main and Auxiliary Consoles must always be located
outside the hazardous area or zone.
Caution should be taken when cleaning plastic surfaces of the iControl 2
pedestal or console. There is a potential for static electricity build up on
these components.
Approval Labels
The following figures show the content of the approvals labels on the
system cabinets.
iControl 2
EN 50177 FM13ATEX0010X
II (2) D
T = +15_to +40_C
A
Vn=100−230VAC fn=50−60Hz Pn=350 VA max.
OUTPUT: Vo(peak)=+/−19V Io(peak)=+/−1.0A
CONTROLLER MUST BE LOCATED IN AN
UNCLASSIFIED LOCATION (ZONE)
NORDSON CORP. AMHERST, OH. USA
Figure 2-6 Label for CE ATEX Approval (On Main and Auxiliary Cabinets)