Nordson iControl Reference guide

iControlrPROFIBUSr, PROFINETr,
DeviceNett, and EtherNet/IPt
Generation 4 Slot 9 Gateway
Customer Product Manual
Part 1605930−02
Issued 03/20
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.

Part 1605930−02 E2020 Nordson Corporation
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
iControl Auxiliary Console 5...................
Electrical Power 6............................
Fieldbus Connection 6.......................
Gateway Circuit Board Jumper Settings 7.......
Software 8....................................
Overview 8..................................
Hardware Requirements 9....................
PCA −PLC Gateway Controller 9............
AnyBus Network Interface Module 9.........
Gateway Software 10..........................
Addressing Modes 11.........................
Broadcast Messages 11.....................
Multicast Messages 11......................
Unicast Messages 11.......................
IO Image Table Configuration 12................
IO Image Table −Module Definitions 12.......
Sending Messages from the PLC 18.............
Broadcast Messages from the
PLC (Module 1) 19.........................
Multicast Messages from the
PLC (Modules 2 and 8) 20..................
Unicast Messages from the PLC 20...........
Flow % Adjust Message 22..................
Reading Data at the PLC −Input Image Table 22..
Gun Monitored Data 23.....................
General System Status 26..................
Gateway Heartbeat 27......................
Parts 28.......................................
Gateway Replacement 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 2014. 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, Prodigy, HDLV, iFlow, Tribomatic, Sure Coat,
Versa-Spray, Nordson, and the Nordson logo are registered trademarks of
Nordson Corporation.
All other trademarks are the properties of their respective owners.

Change Record i
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Change Record
Revision Date Change
01 09/14 New Release.
02 03/20 Internal admin change

Change Record
ii
Part 1605930−02 E2020 Nordson Corporation

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iControlrPROFIBUSr, PROFINETr, DeviceNett,
and EtherNet/IPtGeneration 4 Slot 9 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 Safety Data Sheets (SDS) for all materials used.
Follow the manufacturer’s instructions for safe handling and use of
materials, and use recommended personal protection devices.
STo prevent injury, be aware of less-obvious dangers in the workplace
that often cannot be completely eliminated, such as hot surfaces, sharp
edges, energized electrical circuits, and moving parts that cannot be
enclosed or otherwise guarded for practical reasons.
Fire Safety
To avoid a fire or explosion, follow these instructions.
SDo not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
SProvide adequate ventilation to prevent dangerous concentrations of
volatile materials or vapors. Refer to local codes or your material SDS
for guidance.
SDo not disconnect live electrical circuits while working with flammable
materials. Shut off power at a disconnect switch first to prevent
sparking.
SKnow where emergency stop buttons, shutoff valves, and fire
extinguishers are located. If a fire starts in a spray booth, immediately
shut off the spray system and exhaust fans.
SClean, maintain, test, and repair equipment according to the instructions
in your equipment documentation.
SUse only replacement parts that are designed for use with original
equipment. Contact your Nordson representative for parts information
and advice.

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Grounding
WARNING: Operating faulty electrostatic equipment is hazardous and can
cause electrocution, fire, or explosion. Make resistance checks part of your
periodic maintenance program. If you receive even a slight electrical shock
or notice static sparking or arcing, shut down all electrical or electrostatic
equipment immediately. Do not restart the equipment until the problem has
been identified and corrected.
Grounding inside and around the booth openings must comply with NFPA
requirements for Class II Division 1 or 2 Hazardous Locations. Refer to
NFPA 33, NFPA 70 (NEC articles 500, 502, and 516), and NFPA 77, latest
conditions.
SAll electrically conductive objects in the spray areas shall be electrically
connected to ground with a resistance of not more than 1 megohm as
measured with an instrument that applies at least 500 volts to the circuit
being evaluated.
SEquipment to be grounded includes, but is not limited to, the floor of the
spray area, operator platforms, hoppers, photoeye supports, and
blow-off nozzles. Personnel working in the spray area must be
grounded.
SThere is a possible ignition potential from the charged human body.
Personnel standing on a painted surface, such as an operator platform,
or wearing non-conductive shoes, are not grounded. Personnel must
wear shoes with conductive soles or use a ground strap to maintain a
connection to ground when working with or around electrostatic
equipment.
SOperators must maintain skin-to-handle contact between their hand and
the gun handle to prevent shocks while operating manual electrostatic
spray guns. If gloves must be worn, cut away the palm or fingers, wear
electrically conductive gloves, or wear a grounding strap connected to
the gun handle or other true earth ground.
SShut off electrostatic power supplies and ground gun electrodes before
making adjustments or cleaning powder spray guns.
SConnect all disconnected equipment, ground cables, and wires after
servicing equipment.
Action in the Event of a Malfunction
If a system or any equipment in a system malfunctions, shut off the system
immediately and perform the following steps:
SDisconnect and lock out electrical power. Close pneumatic shutoff
valves and relieve pressures.
SIdentify the reason for the malfunction and correct it before restarting the
equipment.
Disposal
Dispose of equipment and materials used in operation and servicing
according to local codes.

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Description
The iControlrGateway is the interface between an external controller
(usually a PLC) and any of iControl’s dual channel control modules used
with automatic powder guns.
The Gateway converts standard fieldbus protocol messages and
commands (PROFIBUSr, PROFINETr, DeviceNett, or EtherNet/IPt) from
an external 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.
Additional modules are then connected by daisy chaining this network.
The system is compatible with Encorer, Encore HD, Tribomaticr,
Sure Coatr, Versa-Sprayr, PE, and Prodigyrautomatic guns.
External Controller:
PLC, PC, or Robot Controller
Spray Gun
Fieldbus
Wiring
iControl Auxiliary Console
(has no PC touchscreen)
Power
CAN Network
Cable
(Optional)
Gun Cable
Prodigy Pump Panel
Optional
iControl 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 iControl Auxiliary Console
See Figure 2. The Gateway may be inserted into Slot 9 of the iControl card
cage.
NOTE: In some applications, the iControl card cage is mounted in a
custom-built electrical enclosure.
Card Cage
iControl Sub Panel
Slots 1 −8 reserved for
Dual Gun Driver PCAs
Slot 9 for Gateway
iControl Auxiliary Console
Figure 2 Installing Gateway into iControl Auxiliary Console

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Electrical Power
The Gateway requires 24 Vdc @ 100mA (maximum), which is supplied by
the iControl card cage backplane.
Fieldbus Connection
The fieldbus connection is made directly to the Anybusrsupport board.

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Gateway Circuit Board Jumper Settings
Verify that all jumpers and switch settings on the Slot 9 Gateway are
positioned as shown in Figure 3.
JP1
123
Note: No Jumper on JP1
OPEN
12
OPEN
1234
Default Positions for
DIP Switch SW1:
All “Open”
Default Positions for
DIP Switch SW2:
All “Open”
Reference Drawing 10013409_01
See SW2 Configurations
in Table 14 on Page 27.
SW2
Figure 3 Gateway Circuit Board Jumper Settings

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Software
Overview
A typical PLC−based powder system utilizing iControl’s control modules
consists of two basic sub−systems:
Sa PLC which controls the triggering of several guns
Sa network of several intelligent powder flow (either iFlowror Pump Flow
Control PCB [PFCP]) and gun KV control modules.
Since the iControl system uses separate intelligent modules (or nodes) for
controlling powder flow and gun voltage, the PLC, at times, must have the
capability to communicate to 2 nodes for controlling a single gun.
Furthermore, since each flow or KV control node has 2 channels for
controlling two guns, each intelligent node must process data and control
information for 2 separate guns. All of the control nodes are networked
together on a proprietary CAN bus which acts as the channel through which
all data and commands to and from the nodes are sent.
Each Gateway is designed to appear as a single slave device to the PLC
master, regardless of the number of gun control nodes in the system. Inside
the Gateway, the interface between the 2 networks is a dual port memory
device which is organized such that all data/commands have a unique
address which can be accessed by either network.
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 slave nodes, via reading the
dual port memory, is also specified.
Throughout this document, the gun flow, gun pump 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 can be either a gun flow (iFlow) node or a gun pump (PFCP) node,
but not both, to control that gun’s powder flow.

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Hardware Requirements
Figure 4 describes the hardware components which make up the Gateway
system. The PLC master only sees a single slave 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 (PROFIBUS, PROFINET, DeviceNet, 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
S1 bus termination switch (if applicable)
The Anybus module communicates with the PCA via the address and data
bus and some control signals.
Anybus-Module
(PROFIBUS)
(PROFINET)
(DeviceNet)
(EtherNet/IP)
Nordson
CAN
Interface
iControl Gateway
To PLC
To Gun
Control
Nodes
Figure 4 Gateway Hardware

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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 PLC Master To Gun Control Nodes
DSP Firmware Module
(which converts dual port memory
data into CAN messages
and vice versa)
PROFIBUS, PROFINET,
DeviceNet, 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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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 19 for a list of all
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 20 for more
information on multicast messages.
SSend commands and data from the PLC 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 20.
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 PLC master so that its IO
image table matches that of the slave. The module is from the PLC
reference point. The slave is configured at the factory to have the following
16 IO modules:
Table 1 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
8 Output 64 Goto Preset Value (for each gun) C
9 Output 2 Paged Gun General Information
10 Input 12 Paged Gun A Monitored Data/Status
11 Input 12 Paged Gun B Monitored Data/Status
12 Input 12 Paged Gun C Monitored Data/Status
13 Input 12 Paged Gun D Monitored Data/Status
14 Input 8 Global Status and Fault Info
15 Input 1 Heartbeat from Gateway/Slaves
16 Input 8 Paged Gun General Information (4 guns)
NOTE A: The last 3 bytes are never used.
B: The last byte is never used.
C: 1 byte for each of the maximum number of guns which may be used in a system. Since there is a
maximum of 32 guns in the system, the last 32 bytes are not used.
The details of these IO modules are covered in the following sections.
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.

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Output Image Table
See Table 2.
All of the data contained in the Output Image Table are written by the PLC
to its master 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 2) representing locations
in the PLC’s output image table. The fieldbus master sends this data to the
Gateway’s fieldbus slave where the data is written to the dual port memory
by the slave’s 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.
Module 1
When the Gateway detects a new non-zero value in the first byte of Module
1, it will send a broadcast message to all nodes.
Module 2
When the Gateway detects a change has taken place in Module 2, it will
send a multicast message out to the two nodes (KV and Flow/Pump)
associated with the specified gun number.
Module 3
When the gateway detects that a change has taken place in the KV
parameters of Module 3, it will send a unicast message out to the specified
gun’s KV node. If the flow parameters in Module 3 changed, then the
gateway will send a unicast message to the specified gun’s flow (or pump)
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.
Module 4
This 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 4 guns is currently being displayed on the PLC. For
example, if this value were equal to 3, then the PLC is currently displaying
guns #13 thru #16.
Module 5
This module commands all the flow controls to change its flow rates by a
percentage of the setpoint. A detailed description of this module is
discussed on page 22 under Flow % Adjust Message.
Module 6
This 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 light will toggle ON and OFF every
time a new value in Module 6 is stored.

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Module 7
This module is used to permit the PLC to send any unicast messages while
Module 3 is reserved for the efficient handling of Data Table 6 and to quickly
send these parameters to their respective nodes. Module 7 is provided
primarily to send out other unicast messages.
Module 8
The assignment to each gun is sequential, that is to say, the first byte of
Module 8 is assigned to gun #1, the second byte is assigned to gun #2, and
so on. The value in these bytes is a new preset number which is to be used
by a given gun, and is sent to that gun’s KV and Flow node−pair via the
Data Table 14 command (using multicast addressing). When the gateway is
initialized, it will fill this space with zeros indicating to the gateway there is
no change to the current preset (all nodes, by default, start up using preset
#1). It is up to the PLC programmer to initialize this space to contain all
ones, but it is not necessary. The PLC program may change a gun to a new
preset by simply writing to that gun’s byte in Module 8. When the gateway
detects a change has occurred in any of the bytes in this module, it sends a
multicast message out to the node−pair associated with that byte (gun).
Therefore, as the gateway polls its way through Module # 8 looking for
changes, it is possible for it to send out 32 multicast messages; one for
each byte change detected. The last 32 bytes in this module are not used.
Module 9
This module contains 2 bytes. One byte defines which information the
Gateway should present to the PLC. The second byte defines which
grouping of guns to display. This process is similar to module 4 where 0
equals guns 1−4, 1 equals guns 5−8, and so on. For instance, a 1 in the
first byte and a 0 in the second byte will cause the Gateway to pass the gun
node maintenance time for guns 1−4 to the PLC.
All of the above IO Modules are discussed in more detail in later sections.
Table 2 Output Image Table
IO Module
No.
Address
Offset
Size
(Bytes)
Description Range Comment
1 0 1 Broadcast Msg. No. 0−8 0=WAIT
1 1 1 Data Byte 1 0−255 Guns 1−8
1 2 1 Data Byte 2 0−255 Guns 9−16
1 3 1 Data Byte 3 0−255 Guns 17−24
1 4 1 Data Byte 4 0−255 Guns 25−32
1 5 1 Data Byte 5 0−255 Guns 33−40
1 6 1 Data Byte 6 0−255 Guns 41−48
1 7 1 Data Byte 7 0−255 Guns 49−56
1 8 1 Data Byte 8 0−255 Guns 57−64
1 9−11 3Not Used
2 12 1 Gun No. 0−64 0=WAIT
2 13 1 Preset No. 1−255
3 14 1 Edit Node Preset 0−1 0=WAIT
3 15 1 Gun No. 1−64
3 16 1 Preset No. 1−255

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CommentRangeDescriptionSize
(Bytes)
Address
Offset
IO Module
No.
3 17 1 KV 0−100
3 18 1 μA 0−100
3 19 1 AFC 0−1
3 20 1 Select Charge Mode 0−4
3 21 1 Flow Value/Powder
Setpoint
0−160 Common for Standard
and Prodigy
3 22 1 Atomize Value/Pattern
Flow Setpoint
0−160 Common for Standard
and Prodigy
3 23 1 Assist Air
Compensation
-50−+50 Only for Prodigy
3 24 1 Lookup Table 0−3Prodigy Only
3 25 1 Not Used
4 26 1 Gun Page No. 0−15 GUI Gun Page No.
5 27 1 %Adjust On/Off 0−1 0=WAIT
5 28 1 %Adjust−Flow -100−+100
5 29 1 %Adjust−Atomize -100−+100
5 30 1 Not Used
6 31 1 Heartbeat 0−255
7 32 1 Send Unicast Msg 0−20=WAIT, 1=KV,
2=Flow
7 33 1 Gun Number 1−64
7 34 1 Data Table No. 1−255
7 35 1 Parameter Byte 1 0−255
7 36 1 Parameter Byte 2 0−255
7 37 1 Parameter Byte 3 0−255
7 38 1 Parameter Byte 4 0−255
7 39 1 Parameter Byte 5 0−255
7 40 1 Parameter Byte 6 0−255
7 41 1 Parameter Byte 7 0−255
742−43 2Not Used
844−107 64 Preset Number 1−255 For Data Table 14
9 108 1 General Information
Data Type
0−255 0=WAIT, Table 3
9 109 1 Gun Page Number
for Gun General
Information
0−15 GUI Gun Page Number:
associated with next
byte only

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Table 3 Output Image Table −General Information Data Type
Information Data Number Information Data Description
0 WAIT
1Gun Node Maintenance Time
2Flow Node Maintenance Time
3Gun Node Maintenance Minutes (low byte of Module 16, high
byte will be 0)
4Flow Node Maintenance Minutes (low byte of Module 16, high
byte will be 0)
5Gun Node Firmware Version
6Flow Node Firmware Version
7Prodigy Pump Lookup Table
8Gateway S/W Version
9Pump Channel’s A Constant
10 Pump Channel’s C Constant
11 Pattern Channel’s A Constant
12 Pattern Channel’s C Constant
13 PFCP Pump States
14−255 Spare
Input Image Table
See Table 4.
An overview of the Input Image Table modules follows. All of the data
contained in the Input Image Table is written into the dual port memory by
the DSP controller so that the PLC can read it in its master IO space.
Modules 10 through 13
These four are identical 12 byte modules that contain monitored gun
parameter values for four guns. The PLC defines which group of 4 guns is
being displayed on the Operator Interface at any given time by writing the
Gun Page No. into Module 4 of the Output Image Table. The DSP controller
processes this value and places the current monitored parameters for the
group of 4 guns requested by the PLC.
Module 14
This module contains 8 bytes of global status and fault conditions. These
eight bytes provide a quick access to the most important status and alarm
conditions of the system. For example, the lockout state of each gun can be
examined by reading the last byte of module 10 (or 11, 12, 13); however, if
the PLC needs to quickly check if any gun is in lockout, then it can simply
read the first byte of module 14. Address Offset 52 is used to determine the
communication status between Gateway and the Nodes. This byte is
updated every 5 seconds if the Gateway receives any message from any of
the Nodes.
Module 15
This module contains a different value every 1 second so that the PLC may
know that the Gateway’s DSP controller is executing and not locked up.