Nordson iTrax Reference guide

iTraxrSpray Controller
Customer Product Manual
Part 1079459-07
Issued 2/17
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 1079459-07 E2017 Nordson Corporation
Table of Contents
Safety 1.......................................
Qualified Personnel 1.........................
Intended Use 1..............................
Regulations and Approvals 1..................
Personal Safety 2............................
High-Pressure Fluids 2.....................
Fire Safety 3................................
Halogenated Hydrocarbon Solvent Hazards 4.
Action in the Event of a Malfunction 4...........
Disposal 4..................................
Description 5..................................
iTrax Systems 5.............................
iTrax Software Package 6.....................
Optional OPC Remote Client 6..................
Spray Controller Requirements 7...............
EMC Directive Compliance 7..................
Installation 7..................................
Conditions of Warranty 7......................
Spray Controller Configuration 8...............
Spray Machines with Two Spray Guns 10........
Driver and Timer Boards 12....................
Spray Controller Mounting 13...................
Input and Output Connections 14...............
System Wiring 15.............................
Network and Power Connections 17..........
Operation 19...................................
Power Switch 19..............................
LED Indicators 19.............................
iTrax Spray Controller Module Lacquer and Cleanspray
Gun Operation 20.............................
Typical Spray Machine Timing Requirements 20...
Firmware Updates 22............................
Version Compatibility 22.......................
Copying the Flash Drive Files 22................
Reprogramming the iTrax Spray Control Modules . . .
24
Shutting Down the iTrax Software and Server
Applications 24............................
Programming the Module 26.................
Parts 28.......................................
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 2007. 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
iTRAX, CleanSpray, 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
A04 4/10 Updated Fig. 2 jumper settings and signal specification for Gun (MEG)
P201 (page 9).
05 3/15 Added Firmware Update section.
06 8/15 Updated Parts section.
07 2/17 Modified time and driver printed circuit assemblies.

Change Record
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iTraxrSpray Controller
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 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.

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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 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.
SWhile operating manual spray guns, make sure you are grounded.
Wear electrically conductive gloves or a grounding strap connected to
the gun handle or other true earth ground. Do not wear or carry metallic
objects such as jewelry or tools.
SIf you receive even a slight electrical shock, shut down all electrical or
electrostatic equipment immediately. Do not restart the equipment until
the problem has been identified and corrected.
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.
SMake sure the spray area is adequately ventilated.
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.
High-Pressure Fluids
High-pressure fluids, unless they are safely contained, are extremely
hazardous. Always relieve fluid pressure before adjusting or servicing high
pressure equipment. A jet of high-pressure fluid can cut like a knife and
cause serious bodily injury, amputation, or death. Fluids penetrating the
skin can also cause toxic poisoning.
If you suffer a fluid injection injury, seek medical care immediately. If
possible, provide a copy of the SDS for the injected fluid to the health care
provider.

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The National Spray Equipment Manufacturers Association has created a
wallet card that you should carry when you are operating high-pressure
spray equipment. These cards are supplied with your equipment. The
following is the text of this card:
WARNING: Any injury caused by high pressure liquid can be serious. If
you are injured or even suspect an injury:
SGo to an emergency room immediately.
STell the doctor that you suspect an injection injury.
SShow him this card
STell him what kind of material you were spraying
MEDICAL ALERT—AIRLESS SPRAY WOUNDS: NOTE TO PHYSICIAN
Injection in the skin is a serious traumatic injury. It is important to treat the
injury surgically as soon as possible. Do not delay treatment to research
toxicity. Toxicity is a concern with some exotic coatings injected directly into
the bloodstream.
Consultation with a plastic surgeon or a reconstructive hand surgeon may
be advisable.
The seriousness of the wound depends on where the injury is on the body,
whether the substance hit something on its way in and deflected causing
more damage, and many other variables including skin microflora residing
in the paint or gun which are blasted into the wound. If the injected paint
contains acrylic latex and titanium dioxide that damage the tissue’s
resistance to infection, bacterial growth will flourish. The treatment that
doctors recommend for an injection injury to the hand includes immediate
decompression of the closed vascular compartments of the hand to release
the underlying tissue distended by the injected paint, judicious wound
debridement, and immediate antibiotic treatment.
Fire Safety
To avoid a fire or explosion, follow these instructions.
SGround all conductive equipment. Use only grounded air and fluid
hoses. Check equipment and workpiece grounding devices regularly.
Resistance to ground must not exceed one megohm.
SShut down all equipment immediately if you notice static sparking or
arcing. Do not restart the equipment until the cause has been identified
and corrected.
SDo not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
SDo not heat materials to temperatures above those recommended by
the manufacturer. Make sure heat monitoring and limiting devices are
working properly.

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Fire Safety (contd)
SProvide adequate ventilation to prevent dangerous concentrations of
volatile particles or vapors. Refer to local codes or your material SDS
for guidance.
SDo not disconnect live electrical circuits when 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.
SShut off electrostatic power and ground the charging system before
adjusting, cleaning, or repairing electrostatic equipment.
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.
Halogenated Hydrocarbon Solvent Hazards
Do not use halogenated hydrocarbon solvents in a pressurized system that
contains aluminum components. Under pressure, these solvents can react
with aluminum and explode, causing injury, death, or property damage.
Halogenated hydrocarbon solvents contain one or more of the following
elements:
Element Symbol Prefix
Fluorine F “Fluoro-”
Chlorine Cl “Chloro-”
Bromine Br “Bromo-”
Iodine I “Iodo-”
Check your material SDS or contact your material supplier for more
information. If you must use halogenated hydrocarbon solvents, contact
your Nordson representative for information about compatible Nordson
components.
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 system electrical power. Close hydraulic and
pneumatic shutoff valves and relieve pressures.
SIdentify the reason for the malfunction and correct it before restarting the
system.
Disposal
Dispose of equipment and materials used in operation and servicing
according to local codes.

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Description
The Nordson iTrax Spray Controller provides timing control and gun drive
functions for one Nordson spray gun and one CleanSprayrgun as part of a
complete spray control and monitoring system.
This manual covers Spray Controller installation, configuration, and parts.
Refer to the online Help system in the iTrax Operator Interface software for
system configuration, setup, and operation.
The Spray Controller is shipped with two #10 mounting screws, a spare
2.5 amp fuse, and one ribbon cable to connect a second Spray Controller if
required.
264 mm
(10.39 in.)
44 mm
(1.73 in.)
200 mm
(7.87 in.)
Weight: 1.352 kg (2.98 lbs)
Figure 1 iTrax Spray Controller
iTrax Systems
The Nordson iTrax Control System is a configurable spray control and
monitoring system using a combination of modules that communicate over a
CAN network (Controller Area Network) to an OPC Server running on a
Windows computer.
To date, the iTrax modules are:
SSpray Controller modules −one controller for each lacquer spray gun
and CleanSpray gun combination.
SSpray Monitor modules −one monitor for each lacquer spray gun.
SPRx modules −one module for each spray machine or spray gun.

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iTrax Systems (contd)
The Spray Controller, Spray Monitors and PRx modules are connected to a
single CAN network.
The iTrax Operator Interface (OI) is provided as a local OPC client or, as an
option, a remote OPC client. Each module has an independent embedded
processor, so once they are set up on the CAN network, they do not require
the Windows computer to function.
The CAN network is an industrial standard differential serial bus designed to
be robust in electromagnetically noisy environments.
The iTrax System uses a Nordson proprietary data protocol, so only
Nordson modules can be on the network.
External data exchange is provided from the OPC Server. OPC is an
industrial standard that specifies the communication of real−time plant data
between control devices and computers from different manufacturers. The
Nordson iTrax OPC Server is OPC DA 2.0 compliant.
iTrax Software Package
The iTrax Software Package is required for setup and contains the OPC
Server, and OPC Local Client applications.
The OPC Server collects data from the modules on the CAN network once a
second and organizes it per module inputs and outputs. This ”raw” data can
be viewed within the server application.
The OPC Local Client (the iTrax OI) is included on the same CD with the
OPC Server. It runs on the same computer as the OPC Server. The
optional OPC Remote Client (remote iTrax OI) is a remote window into the
system. It provides operators or managers the ability to run or monitor the
iTrax System from remote computers on a factory installed Ethernet
network. The system can also have the following options:
SLocal or Remote OPC data logging software package
SPressure regulators, proximity switches, and other sensors for optional
system control and monitoring
SCAN-to-CAN gateways, for very long networks requiring electrical
isolation or systems with a large number of modules
Optional OPC Remote Client
The optional OPC Remote Client application allows the iTrax system OI to
be viewed and operated on additional computers on your ethernet network.
Talk to your Nordson representative about adding this option to your
system.