Nordson iControl User manual

iControlrStandard Console
Hardware Manual
Customer Product Manual
Part 1105779-04
Issued 09/14
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 1105779-04 E2014 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 2003. 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
iControl, iFlow, Prodigy, Sure Coat, Versa-Spray, Tribomatic, Nordson and
the Nordson logo are registered trademarks of Nordson Corporation.
All other trademarks are the property of their respective owners.

Table of Contents i
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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...........................................
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....................................
iFlow Digital Flow Modules 2-6.............................
Specifications 2-7...........................................
General 2-7..............................................
Air Quality 2-8...........................................
Special Conditions for Safe Use 2-8.........................
Approvals 2-8............................................
Approved Program and User Data Cards 2-9.................

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Installation 3-1.............................................
Introduction 3-1.............................................
CAN Network Connections 3-1...............................
Console CAN Network Address and Termination Settings 3-2..
iFlow Module Dipswitch Settings 3-3........................
Power, Ground, and Relay Connections 3-4....................
iControl Console Power Cable Connections 3-5..............
Conveyor Interlock and Remote Lockout Relay 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..............
25-Conductor Cable Connections 3-10........................
Switching Inputs to Sourcing 3-11..........................
Conveyor Encoder Connections 3-11.........................
Photoeye Connections 3-11.................................
Junction Box and Control Panel Power Requirements 3-11......
Scanner Cable Connections 3-12............................
Discrete Scanner Connections 3-12........................
Analog Scanner Connections 3-13.........................
Customer-Supplied Part ID System Connections 3-14..........
Ethernet Network Connections 3-15............................
iControl Console to Network Interface Box 3-16................
Ethernet Switch to Ethernet Devices 3-16.....................
MAC Addresses 3-16....................................
Connecting Termination Modules to Ethernet Cables 3-17.......
Ethernet Termination Standards 3-19.........................
Gun Cable Connections 3-20..................................
Odd Number of Guns 3-20..................................
Pneumatic Connections 3-21..................................
Supply Air Requirements 3-21...............................
Gun and Pump Air Connections 3-21.........................
Program and User Data Cards 3-22............................
Touch Screen Calibration 3-23.................................
System Upgrades 3-24.......................................
Adding Guns to Existing iControl Console 3-24................
Requirements to Add One Gun 3-25.......................
Procedure: 3-25.........................................
Adding a Slave Console to an Existing System 3-27............
Installing Optional Nozzle Purge Kits 3-27....................

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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..............
Remote I/O (Ethernet) Network Troubleshooting 4-15.............
In/Out Positioner Troubleshooting 4-18.........................
In/Out Positioner Error Code Troubleshooting 4-18.............
Other In/Out Positioner Troubleshooting 4-21.................
Reciprocator Troubleshooting 4-25.............................
Reciprocator Error Code Troubleshooting 4-25................
Other Reciprocator Troubleshooting 4-28.....................
Other Fault Messages and Conditions 4-31......................
Photoeye, Encoder, and Interlock Troubleshooting 4-32...........
Remote Node (FieldBus Controller/Coupler) Troubleshooting 4-33..
FieldBus Status 4-33.......................................
Node Status 4-34..........................................
Voltage LEDs 4-34.........................................
I/O Errors 4-35............................................
Touch Screen Troubleshooting 4-36.............................
Touch Screen Calibration 4-36..............................
Normal Calibration 4-36..................................
Problems During Calibration 4-36.........................
Calibration with a Mouse 4-36.............................
No Touch Screen Display 4-37..............................
Touch Screen Failure 4-38..................................
Screens Display, but Touch Function Does Not Work 4-38....
No Display 4-38.........................................
Rotary Knob Troubleshooting 4-39.............................
Testing Ethernet Cables 4-40..................................
Local Test −Patch Cables 4-40..............................
Remote Test −Cable Run 4-40..............................
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.....................................
iControl PC Replacement 5-6.................................
Ribbon Cable Connections 5-7...............................

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Parts 6-1...................................................
Introduction 6-1.............................................
Consoles 6-3...............................................
Console Parts 6-4..........................................
Control Relays and Fuses 6-12..............................
Flow Module Parts 6-13......................................
Options 6-13................................................
Adapter Cables for Versa-Spray and Tribomatic Spray Guns 6-13
CAN Cable 6-13...........................................
Junction Boxes, Extension Boxes, and Control Panels 6-14.....
Ethernet Components 6-14.................................
Nozzle Purge Kits 6-14.....................................
Miscellaneous Kits 6-14....................................
Recommended Air Filter for Use with iControl Systems 6-14....
Conveyor Encoder 6-15....................................
Photocells and Scanners 6-15...............................
Photocell and Scanner Cables 6-15..........................
Software Replacement Kits 6-16.............................
Wiring and Pneumatic Diagrams 7-1.........................

Change Record i
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Change Record
Revision Date Change
04 09/2014 Re-zero procedure revised

Change Record
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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.

Safety
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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.

Safety 1-3
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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.

Safety
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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.
2. 178475 WARNING: Hot surface. Do not touch.
BAR CODE
BAR CODE
‘
‘
travaux d’entretien.
d’entreprendre des
electrique avant
d’alimentation
les sources
Debranchez toutes
ATTENTION
servicing.
power before
Disconnect all
WARNING
2
1
SERIAL No. XXXXXXX
PART No. XXXXXXX
AUTOMATIC CONTROLS PRODUCT
NORDSON POWDER SYSTEMS
Nordson
2
1
2
1 2 1
2
1 2 1
2
1 2 1
1
2
3
4
567
8
9
10
11
12
13
14
15
16
1
2
Figure 1-1 Safety Labels

Overview 2-1
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Section 2
Overview
iControl System Manuals
This manual covers the iControl console and system hardware for Standard
iControl systems used with Sure Coatr, Versa-Sprayr, and Tribomaticr
spray guns only.
iControl manuals are organized as follows:
Operator Interface Manual covers configuration, preset setup, and
operation using the iControl software and touch screen:
S1056418
Operator Card for all versions:
S1024758
Hardware Manuals, covering installation, troubleshooting, repair, and parts:
SStandard iControl System 1105779
Standard iControl consoles control up to 16 guns per console.
Master Slave
Figure 2-1 iControl Console Styles

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Console and System Hardware and Software
See Figures 2-2 and 2-3. A fully equipped master console controlling 16
spray guns contains the following hardware:
Soperator interface consisting of LCD touch-screen display, rotary dial,
and interlock keyswitch
Ssingle-board computer (PC)
SCompact Flash adapter and two Compact Flash cards, for program and
user data
SI/O board, backplane, card cage, and 8 gun control cards (1 card
controls 2 guns)
Spower supply
Salarm, remote lockout, and conveyor interlock relays
S8 iFlow digital flow modules (1 flow module supplies 2 guns)
S4 preset precision regulators (one regulator supplies two flow modules)
Slave consoles control 16 guns but do not have an operator interface, SBC,
CompactFlash cards, I/O board, or the alarm, lockout, and interlock relays.
The system requires the following external hardware:
Sphotoeye junction boxes
Szone photoeyes or discrete scanners
Spart ID photoeyes or discrete scanners, or inputs from customer part ID
system
Sconveyor encoder
Options
In/Out Positioners (Horizontal or Vertical)
Sanalog scanners (to measure part width)
Sscanner junction box
Sin/out positioners and control panels
Snetwork interface box, Ethernet cables, and Ethernet PCI card
Reciprocators
Sanalog scanners (to measure part height)
Sreciprocators
Sin/out positioner/reciprocator control panels
2nd Booth Option
The 2nd booth shares the signals from the conveyor encoder, zone and part
ID scanners or photoeyes, and positioner and reciprocator scanners.
SEthernet switch installed in scanner junction box

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12
4
3
6
5
8
10
9
7
Figure 2-2 iControl Master Console Internal Components (Shown with Door Opened 90_)
1. iFlow digital airflow modules
2. Regulators
3. CompactFlash cards
4. Computer and LCD display
5. I/O board
6. Card cage, backplane, gun control
cards
7. Power supply
8. Relays and terminal block
9. Air manifold
10. Purge kits (optional)

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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 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.

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CAN and Ethernet Networks
Refer to the system diagrams in Section 7.
CAN Network: Handles communications between the gun control cards,
iFlow modules, and the iControl PC, and with other iControl consoles.
Ethernet Network: Handles communications between the iControl system
and remote devices such as optional in/out positioners, reciprocators, and
scanners.
Digital Inputs
The iControl master console includes an interface 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 for a conveyor interlock
Sone input that locks out guns when any booth exhauster is off (only used
on multiple booth systems using a single iControl)
The encoder and the devices (photoeyes or scanners) or customer inputs
used for zone and part ID detection 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 master
console. If the master console cannot be located within direct wiring range
(19 ft) of the PEJB, an extension box and extra cable is provided. If the
system is equipped with a remote I/O (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.
Resolution: 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 powder spray guns. The cards provide 0−21 Vdc power to the Sure
Coat and Versa-Spray gun voltage multipliers and process feedback from
the guns for display on the operator interface.
For Tribomatic guns, the cards monitor the current feedback and provide the
operator with a reading indicating the electrostatic charge generated in the
guns.
iFlow Digital Flow Modules
The iControl system controls air flow to the spray gun powder pumps,
providing a more consistent and steady flow of powder to the spray guns
than systems that control air pressure. The flow controls consist of the
precision regulators and iFlow digital flow modules mounted in the iControl
enclosure.
One regulator supplies air to two iFlow modules. Each module supplies
flow-rate and atomizing air to two powder pumps, plus gun air (electrode
wash air) to two spray guns. Flow-rate and atomizing air is turned on and
off when the spray guns are triggered on and off.
The modules provide closed-loop control of flow-rate and atomizing air flow,
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 air
flow modules so the closed-loop control 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 modules control the flow of gun air (electrode
wash 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 for continuous flow.
Communication between the iFlow modules and the iControl PC is through
the CAN network.

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Specifications
General
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 (flow-rate,
atomizing)
6.8 m3/hr (4 scfm)
Gun air (electrode wash) 0.36 m3/hr (0.2 scfm)
Electrical Requirements
Input Unswitched: (PC) 100−230 Vac, 50/60 Hz, 1 , 120 VA max.
Switched: 100−230 Vac, 50/60 Hz, 1 , 600VA 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) 0−21 Vdc, 0.60 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

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Air Quality
Air 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.
Special Conditions for Safe Use
SCaution should be taken when cleaning plastic surfaces of the iControl.
There is a potential for static electricity build up on these components.
SThe equipment is intended to be used in the ambient temperature from
0_C to 40_C.
Approvals
FM Approved for US and Canada.
Rated for Class II Division 2, Groups F & G Hazardous Location Area
(North America), or Normal Usage Area.