Nordson iControl Series Manual instruction

iControlrOperator Interface
Configuration, Preset Setup, Operation
Customer Product Manual
Part 1056418-07
Issued 9/19
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.

Part 1056418-07 E2019 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 2005. 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, iFlow, 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
Introduction 1-1............................................
iControl Systems 1-1........................................
Operator Controls 1-2.......................................
Common Interface Objects and Buttons 1-3....................
Help 1-4...................................................
Security System 2-1........................................
Contents 2-1...............................................
Introduction 2-1.............................................
Logging In 2-2..............................................
Logging Out 2-3............................................
Security Configuration 2-3...................................
Creating a User 2-4.......................................
Editing a User 2-4........................................
Setting the Automatic Log Out Timer 2-4....................
Viewing the Security Log 2-5...............................
Security Levels and Access Rights 2-5........................
Standard System Configuration 3-1.........................
Contents 3-1...............................................
Configuration Flowchart 3-2..................................
System Configuration Screen 3-3.............................
Units Configuration 3-4......................................
Guns/Input Card Configuration 3-4............................
Screen Functions Overview 3-4............................
Default Gun Type 3-5.....................................
HDLV Pump Controller Version 3-5.......................
Spectrum HD 3-5......................................
Number of Guns per Console 3-5...........................
Flow Air Upper Limit 3-5...................................
Smart Flow Mode Enable 3-6..............................
Digital Input Card Select 3-6...............................
Manual Mode Lockout 3-6.................................
System Restart 3-7.......................................
Zone Configuration 3-8......................................
Zone Overview 3-8.......................................
Digital Zone Triggering 3-9..............................
Analog Zone Triggering 3-10..............................
Configuring Zone Filters 3-11...............................
Digital Zone Configuration 3-12..............................
Analog Zone Configuration 3-12.............................
Configuring the Auto-Zero Function 3-13...................
Using Zone Inputs for Direct Triggering 3-13..................
Manual Trigger Lockout 3-14.............................
Configuring Part ID Inputs 3-14................................
Straight Flagging 3-15......................................
Encoded Flagging 3-15.....................................
Flag Filter 3-16............................................

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Encoder Configuration 3-17...................................
Encoder Pulse Configuration 3-17...........................
Clock Option 3-17.........................................
Entering a Known Resolution 3-18...........................
Calculating Encoder Resolution 3-19.........................
Fine-Tuning Encoder Resolution 3-20........................
Pickoff Configuration 3-21.....................................
Pickoffs 3-21..............................................
Length of Booth 3-21.......................................
Shift Register Reset 3-22...................................
Triggering Rules 3-22......................................
Standard Gun Purge Configuration 3-24........................
Versa-Spray Nozzle Purge Configuration 3-24.................
Evacuation Purge Configuration 3-27.........................
Soft Start Configuration 3-28................................
Prodigy/Encore HD Gun Purge Configuration 3-29...............
Prodigy HDLV Pump Calibration 3-30........................
Data Backup 3-31............................................
Software and Firmware Versions 3-32..........................
Trace 3-33..................................................
Program Shutdown 3-33......................................
Desktop Utilities 3-34.........................................
Touch Screen Calibration 3-35..............................
Ethernet and Gun Mover Configuration 4-1..................
Contents 4-1...............................................
Introduction 4-2.............................................
System Configuration Screen 4-2.............................
Ethernet Network Configuration 4-3...........................
Network Status Functions 4-3..............................
Host Configuration 4-4....................................
Node Configuration 4-5....................................
iControl Versions Below 3.0 4-5..........................
iControl Version 3 and Above Procedure 4-5...............
Positioner Configuration 4-8..................................
Operating Mode Buttons and Locks 4-9.....................
Actual Position 4-9.......................................
Setting Encoder Resolution 4-9.............................
Setting Zero and Home Positions 4-10.......................
Standard Positioner Configuration Settings 4-10...............
Application-Specific Positioner Configuration Settings 4-12......
Positioning Guns on Horizontal Positioners 4-12...............
Positioning Guns on Vertical Positioners 4-12..................
Move Settings 4-14........................................
Normal Default Move Example 4-15.......................
Lancing Default Moves Example 4-16......................

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Reciprocator Configuration 4-18...............................
Operating Mode Buttons and Locks 4-19.....................
Nordson Service Settings 4-19..............................
Encoder Resolution and Maximum Speed 4-19..............
Accel/Decel Time 4-20...................................
Turn-Around Offset 4-20.................................
Standard Reciprocator Configuration Settings 4-21.............
Application-Specific Reciprocator Settings 4-22................
Operation Mode Settings 4-22............................
Reciprocator Speed Settings 4-22.........................
Fixed Mode 4-23........................................
Oscillator Mode 4-24....................................
Variable Modes 4-24.....................................
Air Flow Percent Adjust Control 4-26.........................
Analog Scanner Configuration 4-28.............................
Analog Scanner Enable 4-28................................
Single In/Out Positioner Scanner Configuration 4-29...........
Dual In/Out Scanner Configuration 4-30......................
Vertical Scanner Configuration 4-30..........................
Vertical Offset (Reciprocators Only) 4-31...................
Setting the Zero Offset Override 4-32......................
Spray Gun Preset Settings 5-1..............................
Contents 5-1...............................................
Introduction 5-1.............................................
Spray Gun Preset Screens 5-2...............................
Spray Gun Control Screen 5-2.............................
Spray Gun Preset Table Screen 5-3.........................
Preset Number and Name 5-4................................
Air Flow Settings for Venturi Pumps 5-5........................
Pressure to Flow Conversion Tables 5-6.....................
Smart Flow Settings for Venturi Pumps 5-7....................
Smart Flow Tables 5-7....................................
Smart Flow Settings −Metric Units 5-9....................
Smart Flow Settings −English Units 5-10...................
Prodigy/Encore HD Air Flow Settings 5-11......................
Electrostatic Settings 5-12....................................
Setting kV 5-13...........................................
Setting AFC 5-13..........................................
Select Charge Mode 5-13..................................
Lead and Lag Settings 5-15...................................
Perfect Pickoff Example 5-16...............................
Extended Spray Example 5-16..............................
Restricted Spray Example 5-17..............................
Extended-Restricted Spray Example 5-17.....................
Zone Assignment 5-18.......................................
Using Zones to Prevent Triggering 5-18......................
Copy All: Gun Control Screen 5-19.............................
Copy All: Preset Table Screen 5-19.............................
Copy Selected: Gun Control Screens 5-20
......................

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Positioner Preset Settings 6-1...............................
Contents 6-1...............................................
Introduction 6-1.............................................
Positioner Preset Settings 6-2................................
Copying Preset Settings 6-3...............................
Saving Preset Settings 6-3................................
Reset to Defaults 6-3.....................................
Using Preset Settings 6-4....................................
Fixed Positioning 6-4.....................................
Variable Positioning −Contouring 6-5.......................
Variable Positioning −Lancing and Contouring 6-6............
Variable Positioning −Lancing into Deep Recesses 6-7........
Reciprocator Preset Settings 7-1............................
Contents 7-1...............................................
Introduction 7-1.............................................
Reciprocator Preset Screens 7-2..............................
Copying Preset Settings 7-2...............................
Saving Preset Settings 7-2................................
Reset to Defaults 7-2.....................................
Fixed Mode Settings 7-3.....................................
Variable Mode Settings 7-5...................................
Reciprocator Preset Percent-Adjust Settings 7-6................
Operation 8-1..............................................
Contents 8-1...............................................
Screen Icons 8-2...........................................
System Startup 8-3.........................................
Using the Console Keyswitch 8-3.............................
Lockout 8-3..............................................
Main Screen Operating Functions 8-4.........................
Global Mode Controls 8-5....................................
Spray Gun Global Control −Manual Spray Control 8-5........
Part ID Control 8-6..........................................
Part ID Modes 8-6........................................
Batch Coating 8-6........................................
Purge Controls 8-7..........................................
Versa-Spray Manual Purge Controls 8-7.....................
Prodigy/Encore HD Purge Controls 8-7......................
Percent Adjust Functions 8-9.................................
Percent Adjust Additive Effects 8-9.........................
Global Percent Adjust 8-9.................................
Conveyor Speed Percent Adjust 8-10........................
Spray Gun Controls 8-11.....................................
Copying Changes to Presets 8-11...........................
Trigger Mode and Manual Triggering 8-11.....................
Turning Individual Guns On and Off 8-12.....................
Positioner Controls 8-13......................................
Positioner Operating Modes 8-13
............................
Control Screen Indicators and Functions 8-13.................
Positioner Homing and Startup Sequence 8-14................
Reciprocator Controls 8-15....................................
Reciprocator Operating Modes 8-15..........................
Control Screen Indicators and Functions 8-15.................
Default and Preset Setting Adjustments 8-16..................
Reciprocator Lap Calculator 8-17............................

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Monitoring Operation 9-1...................................
Contents 9-1...............................................
Gun Monitoring 9-2.........................................
Gun Buttons 9-2.........................................
Global Status Screen 9-2..................................
Global Hourmeter 9-4.....................................
Single Gun Status 9-5.....................................
Gun Hourmeter 9-5.....................................
Part ID 9-6.................................................
Input Status 9-6............................................
Color Change Monitoring 9-7.................................
Alarms 9-8.................................................
Fault Codes 9-8..........................................
Alarm Screen 9-8.........................................
Alarm Log 9-9............................................
Network Status 9-11.........................................
Ethernet Node Status 9-11..................................
Node Status Codes 9-12.................................
Node Error Codes 9-13..................................
CAN Network Status 9-13..................................
CAN Network Errors 9-14................................
Configuration and Preset Records 10-1.......................

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Change Record vii
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Change Record
Revision Date Change
A04 3/10 Updated for version 3.0
A05 5/10 Updated for version 3.2
06 4/13 Updated for versions 3.4 and 3.6
07 09/19 Administrative revision change.

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Introduction 1-1
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Section 1
Introduction
This manual covers Configuration, Preset (Recipe) Setup, and Operation of
the Nordson iControl and iControl 2 Integrated Control Systems. All tasks
described in this manual are accomplished using the iControl Operator
Interface.
NOTE: This version of this manual covers iControl software up to and
including version 3.6. This manual is updated as features are added. If
your software has not been upgraded, you may not have all the screens and
features described here. Contact your Nordson representative for upgrade
information.
iControl Systems
Standard, Encore, and the new iControl 2 systems are used with
venturi-type powder pumps and automatic spray guns supplied by those
pumps. Standard systems are used with Nordson Versa-Spray, Sure Coat
and Tribomatic automatic guns. Encore systems are used with Encore
automatic guns. iControl 2 systems are used with Encore automatic guns.
A system can consist of a master console for the first 16 guns, and a
auxiliary console for guns 17−32. The master console houses the I/O card,
touch screen and computer that runs the iControl software. iControl 2
systems can also consist of an auxiliary console and a pedestal housing the
touch screen, PC, and I/O card.
Prodigy and Encore HD iControl systems control up to 32 spray guns
from each master console. No auxiliary consoles are used.
If the system includes manual guns, the manual gun controllers
communicate with the PC through the system CAN network.
iControl systems control gun triggering and spraying, and gun movers such
as in/out positioners and reciprocators. The system uses signals from
conveyor encoders, photoeyes, light curtains, and proximity sensors to
identify and track the movement of parts through the spray booth and
control the spray guns and gun movers. An Ethernet network is used to
communicate with the gun movers and some part ID system components.
Up to 10 devices can be addressed over the Ethernet network.

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For iControl hardware specifications, installation, troubleshooting, repair,
parts, and wiring diagrams, refer to the following manuals:
SStandard iControl (Sure Coat, Versa-Spray, and Tribomatic: 1105779
SProdigy iControl: 1105820
SEncore iControl: 1105821
SEncore HD iControl: 1603054
SIControl 2: 1603638
These manuals are included on the CD shipped with your iControl system.
Operator Controls
The iControl system runs two sets of software. The operating system is a
real-time industrial operating system. The iControl system software runs on
top of the operating system. When the system boots up, the operating
system screen appears momentarily, then the iControl software loads. The
operating system utilities such as touch screen calibration, are accessed by
performing a Program Shutdown and waiting until the iControl software
shuts down. Refer to Operation for more information.
See Figure 1-1. Use the iControl operator interface to
Sconfigure system devices.
Sset up and adjust spray and gun mover recipes (presets) for parts.
Smonitor and control gun operation and purging.
Scontrol part ID operation.
Smonitor inputs from photoeyes, scanners, and encoders.
Srespond to system alarms.
All setup and operation of the iControl system is done using the Touch
Screen, Rotary Dial (iControl only), and Interlock Keyswitch.
iControl iControl 2
Interlock
Keyswitch
Rotary Dial
Figure 1-1 IControl and iControl 2 Operator Interfaces

Introduction 1-3
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Touch Screen: Touch the buttons, controls, and fields displayed on the
iControl screens to make settings, control system devices, and open and
close screens. The touch screen must be calibrated in order to respond
correctly to your touch. To re-calibrate the touch screen, refer to Section
3, Configuration.
Rotary Dial (iControl 1 only): Use the dial to increase and decrease
numerical values in data fields or to toggle through a range of possible
settings. Select a data field and rotate the dial clockwise to increase;
counterclockwise to decrease.
NOTE: IControl 2 master consoles and pedestals have an enhanced
on-screen keypad with arrow keys that perform the same function as the
rotary dial.
Interlock Keyswitch: The keyswitch has three positions:
SReady: Run system (conveyor on signal is required)
SLockout: Use to shut off guns, in/out positioners, and reciprocators
SConveyor Bypass: Use to trigger guns without a conveyor ON signal
NOTE: Lockout can be overridden for in/out positioners and reciprocators
through their configuration screens.
Common Interface Objects and Buttons
Configure: Touch this button to
open most configuration screens.
Data Fields: Touch a field to select
it, then use the rotary dial or up and
down arrows to edit the field value.
Close: Touch this button to close
open screens.
Keypad: Select a data field, then
touch this button to open the keypad
and enter values.
Radio Buttons: Touch a button to
select an option. Only one button in
a group can be selected.
OK: Touch to acknowledge a
message, proceed with an action, or
enable a feature.
Drop-down Fields: Touch the field
to open a drop-down list and select
a value.
Cancel: Touch to cancel changes
or an action, or disable a feature.

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Help
Touch the Help button on the Main screen to open the Help screen.
Tap on blue underlined links to jump from one topic to another.
The Previous and Next buttons jump to previously opened pages. The
Home button and the HOME link at the bottom of each page jump to the
home page. Touching the Top button returns you to the top of the page.
Use the scroll bars on the right side of the page to scroll up and down the
page.
Close Previous Next Home Top
Scroll Bar
Figure 1-2 Help Screen

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Section 2
Security System
Contents
Introduction 2-1.............................................
Logging In 2-2..............................................
Logging Out 2-3.............................................
Security Configuration 2-3....................................
Creating a User 2-4.......................................
Editing a User 2-4.........................................
Setting the Automatic Log Out Timer 2-4.....................
Viewing the Security Log 2-5...............................
Security Levels and Access Rights 2-5.........................
Introduction
A new iControl system, at power up, starts with the security system
disabled. All iControl screens and functions (except for those restricted to
Nordson representatives only) are available to any user.
Use the Security Configuration screens to set up users, define their access
levels, and create passwords.
Touch the Security button on the Main screen to open the Log In/Log Out
screen.
SIf the security system is disabled the Configure button is automatically
enabled.
SIf no user is logged in, then the Log Out button is grayed out and no
user name is displayed.
Log In Log Out
Configure
User
021
Figure 2-1 Log In/Out Screen

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Introduction (contd)
On a new system, touching the Configure button displays the security
configuration screen but all functionality is disabled. The security system
must be set up by a Nordson Customer Service Representative or
engineer. When the CSR logs in the security configuration functionality is
enabled. Once the security system is enabled and configured, the Security
Configuration screen is only available to a user with level 4 access rights.
NOTE: Even if the security system is disabled, Nordson representatives still
have to log in to access the Nordson−only system configuration settings.
Access to screens and functions depends on the security level assigned to
the user. Refer to the security access table on page 2-5 for a list of access
rights by function and user level.
Logging In
Only one user can be logged in at a time. When a new user logs in the
previous user is automatically logged out.
1. See Figure 2-2. Touch the Log In button on the Log In/Out screen to
open the Log In screen.
User Name
Password
OK
014
Figure 2-2 Logging In
2. Touch the User Name field and select your user name.
3. Touch the Password field. The keyboard opens. Enter your password
on the keyboard screen. Passwords are case-sensitive.
4. Close the keyboard.
5. Touch the OK button to log in.

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Logging Out
See Figure 2-1. Touch the Log Out button. A confirmation window opens.
Touch the OK button to log out; touch the Cancel button to cancel the
action.
NOTE: Users with supervisor access rights (level 4) can set an automatic
log out timer that starts when no activity is detected and logs them out
when the timer runs out.
Security Configuration
See Figure 2-1. Touch the Configure button to open the Security
Configuration screen:
4
123
13
12
11
10
9
87
5
6
Create/Edit
User
Select
Existing
User
Automatic
Logout
015
Figure 2-3 Security Configuration Screen
1. Enable/disable security system
2. User name drop-down
3. Selected user level
4. Selected user password
5. OK changes
6. Delete (erase) user
7. Automatic logout timer (minutes)
8. Enable/disable automatic logout
9. Security log
10. Re-enter password
11. Password
12. Security level
13. User name

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Creating a User
See Figure 2-3. Use the Create/Edit User area.
1. Enter a user name in the User Name field (13).
2. Select a security level from the Security Level drop-down list (12).
Refer to the Security Levels and Access Rights table on page 2-5.
3. Enter a Password, once in each password field (11, 10). Passwords
are case-sensitive.
4. Touch the OK button (5). To delete the user touch the Delete button (6).
NOTE: All fields must be filled out correctly, or one of the following
graphical error messages appears:
User Name
Error
Security Level
Error
Password
Error
Figure 2-4 User Error Messages
Editing a User
1. See Figure 2-3, Select Existing User area. Select a User name (2). The
user name, security level, and password appears in the Create/Edit
fields.
2. Edit the fields as desired, then touch the OK button (5).
3. To delete the user touch the Delete button (6).
Setting the Automatic Log Out Timer
See Figure 2-3. Automatic log out only applies to supervisor-level (level 4)
users. To set up automatic logout:
1. Enable automatic log out (8).
2. Set the timer (7). Time is in seconds (0−999).
A clock icon appears next to the user name on the Main screen when
automatic log out is enabled. The timer starts when no activity in the user
interface is detected, and the user is logged out when the timer expires.
NOTE: Automatic logout is always enabled for Nordson CSRs and
Engineers and cannot be changed or disabled for them.

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Viewing the Security Log
See Figure 2-3. Touch the Security Log button (9) to open the Security
Log. The log file contains a list of user names and the times they logged in
and out.
Only a Nordson representative can erase the log file. The Erase button is
inactive for all other users.
Security Levels and Access Rights
The following table lists the access rights for all screens and functions.
Level 4: Supervisor
Level 3: Lead
Level 2: Operator
Level 1: No one logged in
Security Access Rights for Screens and Functions
Security Level Required
Screen Button Viewing Changing
Main Screen Alarm All —
Global Status All —
Percent Adjust All —
Preset Table All —
Nozzle Purge All —
Gun Mover Preset All 3, 4
Reciprocator Preset All 3, 4
System Configuration All —
Part ID Status All —
Help All —
Gun Buttons All —
Part ID All —
Security All —
Alarm Reset All Alarms All 2, 3, 4
Alarm Log All 3, 4
Help All —
Global Gun Status CA/CB (Consoles A, B) All —
Percent Adjust Flow Air All 2, 3,4
Atomizing Air All 2, 3, 4
Continued...
Preset Table All preset settings All 3, 4
Save — 3, 4
Nozzle Purge Auto All 2, 3, 4
Manual All 2, 3, 4
- Purge All —2, 3, 4

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ChangingViewingButtonScreen
Trigger Mode Auto — 2, 3, 4
Manual — 2, 3, 4
- Preset Number —2, 3, 4
- Trigger All —2, 3, 4
Off — 2, 3, 4
In/Out Positioner and
Reciprocator Presets
Preset settings 2, 3 4
Copy All 2, 3 4
Save 2, 3 4
Help All buttons All —
Security Login/Logout All All
Configuration All 4
Gun Control Trigger Mode/Trigger All 2. 3. 4
Preset Number/Name All 3, 4
Preset settings All 3, 4
Copy Functions All 3, 4
Part ID Auto All 2, 3, 4
Manual All 2, 3, 4
Manual Part ID select/enter All 2, 3, 4
System Configuration Conveyor Encoder All 4
Photoeyes and Scanners All 4
Pickoff All 4
Consoles/Guns All 4
Purge All 3, 4
In/Out Positioners All 3, 4
−Positioner Encoder All Nordson Only
Reciprocators All 3, 4
−Reciprocator Encoder All Nordson Only
−Maximum Speed All Nordson Only
−Turn Around Fine Tuning All Nordson Only
Network Status All —
Network −Host Configuration All Nordson Only
Network −Node Configuration All Nordson Only
Units All 4
Data Backup All 4
Shutdown All 2, 3, 4
About (software versions) All —