Nordson Encore HD iControl System User manual

EncorerHD iControlrSystem
Hardware Manual
Installation, Troubleshooting, Repair, Parts
Part 1603054-02
Issued 4/15
NORDSON CORPORATION AMHERST, OHIO USA
C
APPROVED
US
FM
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.
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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, Sure Coat, Prodigy, Nordson and the Nordson logo are
registered trademarks of Nordson Corporation.
All other trademarks are the properties of their respective owners.
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Change Record
Revision Date Change
01 03/13 Released
02 04/15 Removed part numbers from parts list.
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Table of Contents iii
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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.......................................
iControl System Manuals 2-1.................................
Console and System Hardware and Software 2-2...............
Options 2-2..............................................
Operator Interface 2-4....................................
Interlock Keyswitch Functions 2-4........................
CAN and Ethernet Networks 2-5............................
Digital Inputs 2-5.........................................
Encoder 2-5...........................................
Gun Control Cards 2-6....................................
Gun Pump Control 2-6....................................
Specifications 2-6...........................................
General 2-6..............................................
HDLV Pump and Spray Gun Pattern Air Quality 2-7...........
Special Conditions for Safe Use 2-7.........................
Approvals 2-7............................................
Approved Program and User Data Cards 2-9.................
Installation 3-1.............................................
Introduction 3-1.............................................
System Diagram 3-2........................................
Hardware Installation 3-2....................................
CAN Network Connections and Settings 3-3....................
iControl Console CAN Address and Termination Settings 3-4...
Manual Gun Controller Addresses 3-4.......................
Manual Gun Controller Termination 3-4......................
Pump Control Card Configuration 3-5.......................
Power, Ground, and Relay Connections 3-5....................
Console Power Cable Connections 3-5......................
Conveyor Interlock and Remote Lockout 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..............
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Encoder, Zone, and Part ID Connections 3-9...................
25-Conductor Cable Connections 3-10........................
Switching Inputs to Sourcing 3-11..........................
Conveyor Encoder Connections 3-11.........................
Photoeye Connections and Configuration 3-11................
Scanner Cable Connections 3-11............................
Discrete Scanner Connections 3-11........................
Analog Scanner Connections 3-12.........................
Customer-Supplied Part ID System Connections 3-13..........
Ethernet Network/Gun Mover Control 3-13......................
Gun Cable and Feed Tubing Connections 3-15..................
Odd Number of Guns 3-15..................................
Program and User Data Cards 3-16............................
Touch Screen Calibration 3-17.................................
System Upgrades 3-17.......................................
Troubleshooting 4-1........................................
Error Codes and Alarm Messages 4-1.........................
CAN Network Errors 4-6.....................................
Gun Card Troubleshooting 4-7................................
Gun Card Error Codes and Fault Codes 4-7..................
Gun Card LEDs 4-9.......................................
HDLV Pump Troubleshooting 4-11.............................
Pump Controller Error Codes 4-11...........................
Air Flow Re-Zero Procedure 4-12............................
Re-Zero Procedure 4-12.................................
Ethernet Network Troubleshooting 4-14.........................
In/Out Positioner Troubleshooting 4-16.........................
In/Out Positioner Error Code Troubleshooting 4-16.............
Other In/Out Positioner Troubleshooting 4-19.................
Reciprocator Troubleshooting 4-23.............................
Reciprocator Error Code Troubleshooting 4-23................
Other Reciprocator Troubleshooting 4-26.....................
Other Fault Messages and Conditions 4-29......................
Photoeye, Encoder, and Interlock Troubleshooting 4-30...........
Touch Screen Troubleshooting 4-31.............................
Touch Screen Calibration 4-31..............................
Normal Calibration 4-31..................................
Problems During Calibration 4-31.........................
Calibration with a Mouse 4-31.............................
No Touch Screen Display 4-32..............................
Touch Screen Failure 4-33..................................
Screens Display, but Touch Function Does Not Work 4-33....
No Display 4-33.........................................
Rotary Dial Troubleshooting 4-33..............................
Testing Ethernet Cables 4-34..................................
Local Test −Patch Cables 4-34..............................
Remote Test −Cable Run 4-34..............................
Repair 5-1.................................................
Gun Control Card Removal/Installation 5-1.....................
iControl PC Replacement 5-3.................................
Ribbon Cable Connections 5-4.............................
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Parts 6-1...................................................
Introduction 6-1.............................................
Console Part Number List 6-2................................
Console Parts 6-3..........................................
Junction Boxes, Extension Boxes, and Control Panels 6-8........
Ethernet Components 6-8....................................
Conveyor Encoder 6-8.......................................
CAN Cable 6-8.............................................
Photocells and Scanners 6-9.................................
Photocell and Scanner Cables 6-9..........................
Wiring Diagrams 7-1........................................
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Safety 1-1
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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.
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Personal Safety
To prevent injury follow these instructions.
SDo not operate or service equipment unless you are qualified.
SDo not operate equipment unless safety guards, doors, or covers are
intact and automatic interlocks are operating properly. Do not bypass or
disarm any safety devices.
SKeep clear of moving equipment. Before adjusting or servicing any
moving equipment, shut off the power supply and wait until the
equipment comes to a complete stop. Lock out power and secure the
equipment to prevent unexpected movement.
SRelieve (bleed off) hydraulic and pneumatic pressure before adjusting or
servicing pressurized systems or components. Disconnect, lock out,
and tag switches before servicing electrical equipment.
SObtain and read Material Safety Data Sheets (MSDS) for all materials
used. Follow the manufacturer’s instructions for safe handling and use
of materials, and use recommended personal protection devices.
STo prevent injury, be aware of less-obvious dangers in the workplace
that often cannot be completely eliminated, such as hot surfaces, sharp
edges, energized electrical circuits, and moving parts that cannot be
enclosed or otherwise guarded for practical reasons.
Fire Safety
To avoid a fire or explosion, follow these instructions.
SDo not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
SProvide adequate ventilation to prevent dangerous concentrations of
volatile materials or vapors. Refer to local codes or your material MSDS
for guidance.
SDo not disconnect live electrical circuits while working with flammable
materials. Shut off power at a disconnect switch first to prevent
sparking.
SKnow where emergency stop buttons, shutoff valves, and fire
extinguishers are located. If a fire starts in a spray booth, immediately
shut off the spray system and exhaust fans.
SClean, maintain, test, and repair equipment according to the instructions
in your equipment documentation.
SUse only replacement parts that are designed for use with original
equipment. Contact your Nordson representative for parts information
and advice.
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Grounding
WARNING: Operating faulty electrostatic equipment is hazardous and can
cause electrocution, fire, or explosion. Make resistance checks part of your
periodic maintenance program. If you receive even a slight electrical shock
or notice static sparking or arcing, shut down all electrical or electrostatic
equipment immediately. Do not restart the equipment until the problem has
been identified and corrected.
All work conducted inside the spray booth or within 1 m (3 ft) of booth
openings is considered within a Class II, Division 1 or 2 Hazardous location
and must comply with 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.
Refer to the Installation section of this manual for more information on
grounding.
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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Safety Labels
Table 1-1 contains the text of the safety labels on the iControl console. 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.
`
`
travaux d'entretien.
d'entreprendre des
electrique avant
d'alimentation
les sources
Debranchez toutes
ATTENTION
servicing.
power before
Disconnect all
WARNING
1
Figure 1-1 Safety Labels
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Section 2
System Overview
iControl System Manuals
This manual covers the iControl console and system hardware for Encore
HD systems, used with Encore HD spray guns only.
iControl manuals are organized as follows:
Operator Interface Manual for all versions of the system, covering
configuration, preset setup, and operation using the iControl software:
S1056418
Operator Card for all versions:
S1024758
and this manual.
An Encore HD iControl system console controls up to 32 automatic guns.
Figure 2-1 Prodigy iControl Console
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Console and System Hardware and Software
See Figures 2-3 and 2-2.
A fully equipped console controlling 32 Encore HD automatic spray guns
contains the following hardware:
Soperator interface consisting of LCD touch-screen display, rotary dial,
and interlock keyswitch
Ssingle board computer (SBC), with Ethernet PCI card
Stwo CompactFlash cards, for system software and user data
SI/O board, two subpanels with backplanes, card cages, and 16 gun
control cards (one card controls two guns)
S24Vdc power supplies
Salarm, remote lockout, and conveyor interlock relays
The system requires the following external hardware:
Sphotoeye junction box
Szone photoeyes or discrete scanners
Spart ID photoeyes or discrete scanners, or inputs from customer part ID
system
Sconveyor encoder
Sconveyor interlock relay
Snetwork interface box
Sfeed center, with four pump panels containing 32 HDLV pumps and 16
control cards (one card controls two pumps)
Options
In/Out Positioners (Horizontal or Vertical): Move guns toward and away
from parts according to the settings you make in the iControl software.
Positioners allow contouring, where the gun tips are kept at the same
distance from the part as the part width changes. They also allow lancing,
where the guns can be moved to coat the inside of a part cavity as the part
passes by.
Reciprocators: Move guns vertically as the part passes by. The
reciprocator motion is programmed through the iControl operator interface.
To use these devices requires adding the following external devices to the
system:
Sanalog scanners to measure part width and height.
Sscanner junction box and controllers.
SEthernet network and switch
SPLCs and VFDs
2nd Booth Option: 2nd booth shares encoder signal, zone and part ID
signals, and if in/out positioners and reciprocators are used, scanner
signals.
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2
34
11 897
56
12
L2L2 L1L1 L2L1
240V
240V
PE
240V240V
A1 A2
14
11 12
A1 A2
14
11 12
A1 A2
14
11 12
10
Note: Back of computer shown without upper cover.
Figure 2-2 iControl Encore HD Console Internal Components
1. Keypad
2. 3-Position interlock switch
3. Computer and LCD display
4. CompactFlash cards
5. Power supply
6. Card cage with gun control cards
7. Gun cable receptacles
8. Power switch
9. Relays and fuses
10. I/O and interface cards
11. I/O board
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Operator Interface
The iControl software provides a graphical user interface that provides
screens to configure and control the spray gun triggering and positioning
system.
The operator performs all configuration and operation tasks with the touch
screen and the Rotary Dial. Turning the rotary dial increases or decreases
values in selected fields.
3
2
1
Figure 2-3 Master Console Front Panel
1. Interlock keyswitch
2. LCD touch screen
3. Rotary dial
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 and the gun movers are disabled. Use
this position when working inside the booth.
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CAN and Ethernet Networks
Refer to the system diagram in Section 7.
CAN Network: Handles internal communications between the gun control
cards, iFlow modules, and the iControl PC, and with other iControl consoles.
Ethernet Network: Handles external communications between the iControl
system and remote devices such as optional in/out positioners,
reciprocators, and analog scanner controllers.
Digital Inputs
The iControl console includes an I/O board that provides optically isolated
digital inputs. Included are
Seight inputs for zone detection
Seight inputs for part identification
Sone input for a conveyor motion encoder
Sone input that locks out guns when any booth exhauster is off (only used
on multiple booth systems using a single iControl)
The encoder, zone and part ID photoeyes or discrete (digital) scanners with
or customer part ID inputs are connected to a terminal block in the
Photoeye Junction Box (PEJB). A 24Vdc power supply in the PEJB
provides power for these devices.
A 25-conductor input cable connects the PEJB to the iControl console. If
the console cannot be located within direct wiring range (19 ft) of the PEJB,
an extension box and extra cable are provided. If the system is equipped
with a Ethernet network, then the 25-conductor cable is routed through a
network junction box.
Encoder
The iControl system provides one optically isolated digital input for a
conveyor motion encoder. The encoder can be either mechanical or optical
and must have a 50% duty cycle.
At an encoder resolution of one inch to one pulse (1:1), the effective
distance parts can be tracked by the iControl 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 timer may be used instead of an encoder. Consult with your
Nordson representative.
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Gun Control Cards
Each gun control card in the card cage provides electrostatic controls for
two Encore HD automatic powder spray guns. The cards provide AC power
to the voltage multipliers (power supplies) in the automatic guns, and
process feedback from the guns for display on the operator interface.
Encore HD manual spray guns are controlled by the manual gun controllers.
Gun Pump Control
The iControl console and the manual gun controllers control the HDLV
powder pumps through the CAN network. In the pump cabinet, one pump
control card controls two pumps.
Refer to the HDLV pump and pump panel manuals for wiring diagrams,
parts lists, and other information.
Specifications
General
Electrical Requirements
Input Unswitched: (PC) 100−230 Vac, 50/60 Hz, 1 , 120 VA max.
Switched: 100−230 Vac, 50/60 Hz, 1 , 480VA max.
Conveyor Interlock and 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) 19 Vac, 1 A
NOTE: The iControl 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 32−104 _F (0−40 _C)
Operating Humidity 5−95%, non-condensing
Hazardous Location Rating North America: Class II Division 2, Groups F & G
European Union: Ex II 3D
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HDLV 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 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 HDLV pumps to malfunction; the
powder to cake in the reclaim system, or clog the feed tubing, and spray
gun powder paths.
Special Conditions for Safe Use
Caution should be taken when cleaning plastic surfaces of the iControl.
There is a potential for static electricity build up on these components.
The Encore HD Powder Electrostatic Automatic Applicators shall only be
used with the associated Encore HD iControl Controllers over the ambient
temperature range of +15 _C to +40 _C (59 _F to 104 _F).
Approvals
See Figure 2-4 for the approval labels affixed to the equipment.
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ENCORE HD iControl
1180
EN50177 FM13ATEX0007X
(2) 3 D
Ex tc IIIB T60_C
T = +15 to +40_C
A
NORDSON CORP. AMHERST, OH. USA
Vn = 100-230 Vac n = 50-60 Hz Pn = 600 VA
OUTPUT: Vo (peak) = 19V Io (peak) = 1.0 A
WARNING - POTENTIAL ELECTROSTATIC CHARGING
HAZARD, SEE INSTRUCTION MANUAL.
ENCORE HD iCONTROL
AUTOMATIC POWDER
SPRAY SYSTEM
FOR ELECTROSTATIC
FINISHING APPLICATION
USING CLASS II SPRAY MATERIAL WHEN
CONFIGURED IN ACCORDANCE WITH 10011656;
CONTROLLER IS SUITABLE FOR CLASS II
DIVISION 2, GROUP F & G HAZARDOUS
(CLASSIFIED) LOCATIONS.
Figure 2-4 iControl Encore HD Approval Labels
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