Nordson Encore HD iControl 2 Installation, Troubleshooting, Repair Download Page 13

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2-1

Overview

1609758-04

Section 2

Overview

System Manuals

This manual covers the iControl 2 system hardware for Encore

HD iControl

2 systems

used with Encore automatic spray guns.
iControl 2 manuals are organized as follows:

Operator Interface Manual:

Covers configuration, preset setup, and operation using the

iControl 2 software and touch screen.

• 1056418

Operator Card:

for all versions of the iControl 2 systems.

• 1024758

Hardware Manual:

Covers installation, troubleshooting, repair, parts, and drawings for

this system only.
The Encore HD iControl 2 systems can consist of a main console, an auxiliary console,

and a pedestal system. Each system can support up to 32 spray guns.

Main Console

Auxiliary Console

Pedestal System

Figure 2-1 iControl 2 Consoles and Pedestal

Summary of Contents for Encore HD iControl 2

Page 1: ...r 1609758 04 Issued 03 22 For parts and technical support call the Industrial Coating Systems Customer Support Center at 800 433 9319 or contact your local Nordson representative This document is subj...

Page 2: ...n Street Amherst OH 44001 Notice This is a Nordson Corporation publication which is protected by copyright Original copyright date 2017 No part of this document may be photocopied reproduced or transl...

Page 3: ...2 4 DC Power Supplies 2 5 Dual Spray Gun Cards 2 5 Spray Gun Pump Control 2 5 Internal and External Networks 2 5 Digital Inputs 2 6 Conveyor Encoder 2 6 Specifications 2 7 General 2 7 Prodigy Pump an...

Page 4: ...ata Cards 3 22 Touch Screen Calibration 3 23 System Upgrades 3 23 Optional Air Conditioner Installation and Operation 3 24 Troubleshooting 4 1 Error Codes and Alarm Messages 4 2 CAN Network Errors 4 7...

Page 5: ...ctions 5 4 Touch Screen Replacement 5 5 Touch Screen Replacement contd 5 6 Parts 6 1 Introduction 6 1 iControl 2 Controllers 6 1 Interconnect Cables 6 3 Main Auxiliary Console Parts 6 4 Main Auxiliary...

Page 6: ...2022 Nordson Corporation 1609758 04 iv Table of Contents...

Page 7: ...1609758 04 Change Record Revision Date Change 01 10 17 New Release 02 08 18 Added Rev 2 Arbor PC to parts list and sections regarding program and data cards Updated wiring diagrams 03 02 22 Updated ap...

Page 8: ...2022 Nordson Corporation 1609758 04 ii Change Record...

Page 9: ...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...

Page 10: ...sion follow these instructions Ground all conductive equipment Use only grounded air and fluid hoses Check equipment and workpiece grounding devices regularly Resistance to ground must not exceed one...

Page 11: ...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...

Page 12: ...ontrol master and auxiliary cabinets and on the rear of the pedestal The safety labels are provided to help operate and maintain the console safely See Figure 1 1 for the location of the safety labels...

Page 13: ...ion preset setup and operation using the iControl 2 software and touch screen 1056418 Operator Card for all versions of the iControl 2 systems 1024758 Hardware Manual Covers installation troubleshooti...

Page 14: ...in the main console Standard System Functions Standard iControl 2 system functions control spray gun triggering electrostatic charging and powder flow and velocity Up to 255 part recipes presets can b...

Page 15: ...ed stroke lengths Oscillators are typically controlled from the main system control panel 1 2 3 4 5 6 7 3 5 4 Figure 2 2 iControl 2 Main Console and Pedestal Internal Components 1 Dual spray gun cards...

Page 16: ...d be completely shut down before turning off console power Interlock Keyswitch Functions In the Ready position the spray guns cannot be triggered unless the conveyor is running This prevents powder wa...

Page 17: ...anual spray gun controllers control the Prodigy HDLV powder pumps through the CAN network In the pump cabinet one pump control card controls two pumps Refer to the Prodigy HDLV pump and pump panel man...

Page 18: ...ond junction box may be used depending on the number and type of scanners in the system A cable connects the part ID junction box to the iControl 2 main console or pedestal The cable plugs into the PD...

Page 19: ...on Rating See Note A Class II Division 2 Groups F G Zone 22 area NOTE A Only the iControl 2 Pedestal is certified for hazardous locations or zones The Main and Auxiliary Consoles must always be locate...

Page 20: ...s and Display Pedestal with Main Console for Pedestal shall be installed in a non explosive atmosphere location CAUTION Caution should be taken when cleaning plastic services on the Encore HD iControl...

Page 21: ...2022 Nordson Corporation 1609758 04 2 9 Overview 1610723 03 Figure 2 5 Label for Approval Pedestal Cabinet Figure 2 6 Label for FM Approval On Main Auxiliary and Pedestal Cabinets...

Page 22: ...2022 Nordson Corporation 1609758 04 2 10 Overview Console Dimensions 609 6 mm 24 in 1634 mm 64 3 in 611 mm 24 06 in 581 5 mm 22 8 in Figure 2 7 Console Dimensions...

Page 23: ...2022 Nordson Corporation 1609758 04 2 11 Overview Pedestal Dimensions 460 mm 18 1 in 457 2 mm 18 in square base 1385 mm 54 5 in 386 mm 15 2 in Figure 2 8 Pedestal Dimensions...

Page 24: ...g of 2 000 000 write cycles and an increased temperature range to 85 C 185 F NOTE Both the Program and Data cards should be the same size and from the same manufacturer If they are not of the same siz...

Page 25: ...only basic installation information Detailed information is contained in the system wiring diagrams plan views and other documentation furnished by Nordson application engineering Once all hardware is...

Page 26: ...CA1 PC1 CB1 OPTIONAL Part ID Conveyor Encoder PM2 To Pump Panel Part ID Stand ETHERNET ETHERNET Gun Movers Motors and Sensors System Electrical Panel PM2 PM1 CA1 FCPW AC Power To Powder Feed Center AC...

Page 27: ...y gun mover control and for powder feed center color change sequence PM2 Ethernet signals from analog scanners for spray gun mover control PJ1 Signals between pedestal and console 12 and 24V to pedest...

Page 28: ...AC IN Cable CA1 Optional Cable PC1 CAN to Pump CB1 Console Ground Ethernet PM1 Part ID Cable PD1 Spray Gun Cable Connections Blank Plate See Note Figure 3 2 Console Rear Panel Cover Removed NOTE For...

Page 29: ...ductor Twisted Pair Shielded Cable Dust Tight Conduit Connector or Strain Relief Field Connections Network Interface Box BLUE WHT BLUE BLUE WHT BLUE OUT OUT OUT IN IN OUT OUT IN IN GND BLUE WHT BLUE B...

Page 30: ...3 4 System Interconnect Cable Connections Manual Spray Gun Controller Addresses The manual spray gun controller addresses are set through software Each controller must have a unique address Up to four...

Page 31: ...ol card address and spray gun type switches The termination jumper must be installed on W1 pins 1 and 2 on the last pump control card in the last pump cabinet on the feed center NOTE The calibration n...

Page 32: ...Common PC Supply 1 Manual Enable 9 Keyswitch Conveyor Bypass 2 Manual Enable 10 Keyswitch Lockout 3 Gun Power OK 11 Main Backplane Lockout P2 4 4 Gun Power OK 12 Main Backplane Lockout P2 3 J4 Low Vo...

Page 33: ...4 24 Vdc Power ON 24 Vdc source is functioning properly OFF 24 Vdc source not functioning properly Check wiring relay board and power supply 5 Conveyor ON Conveyor run signal present or keyswitch is...

Page 34: ...0V in the future the power supply MUST be switched to 230V before connecting power to the console Table 3 2 lists the connections required for both main and auxiliary consoles Console Power Cable Conn...

Page 35: ...tacts an electrical enclosure or other conductive component The ground conductor wire carries the electrical current directly to ground and short circuits the input voltage until a fuse or circuit bre...

Page 36: ...controller through a ground braid and back to the spray gun through the spray gun driver board The current attracted to the booth is returned through the booth ground to the controller and back to the...

Page 37: ...not to a panel enclosure or other component bolted to the base Keep the cables as short as possible If using a grounding block kit make sure the block is installed directly to the base with the inclu...

Page 38: ...own Part ID bit 4 13 White Red Part ID bit 5 14 White Orange Part ID bit 6 15 White Yellow Part ID bit 7 16 White Green Part ID bit 8 17 White Blue Trigger Bank 0 18 White Violet Trigger Bank 1 19 Whi...

Page 39: ...ction Box The PEJB houses a 24 Vdc power supply terminal block and scanner controllers The box is typically mounted on the legs of the part ID stand The part ID cable and the encoder conveyor interloc...

Page 40: ...as shown Discrete Scanner Connections Single Zone Scanner SCNR1 cables to scanner Dual Zone Scanners SCNR1 cables to upper scanner SCNR2 cables to lower scanner Part ID Scanner and Zone Scanner SCNR1...

Page 41: ...ngle horizontal scanner the scanner controller must be programmed to ignore the conveyor Maximum Emitter Receiver Separation 6 meters 20 ft if scanner is less than 1 22 meters 4 ft long 4 6 meters 15...

Page 42: ...l 2 system to communicate with the spray gun mover PLCs and the analog scanner controllers through a network switch in the Main Electrical Control Panel The Ethernet cables are M12 D coded 4 pole cabl...

Page 43: ...2 System with Main Console iControl 2 System with Pedestal iControl 2 Main Console Analog Scanner Controllers System Electrical Control Panel PLCs Switch PM1 PM2 iControl 2 Pedestal Analog Scanner Co...

Page 44: ...ems are sold configured for an even number of spray guns Each spray gun controller card in the console controls two spray guns If the system is configured for an odd number of spray guns the fault LED...

Page 45: ...9758 04 3 21 Installation 1 2 3 4 5 6 7 8 Receptacle 8 Bulkhead Seal Harnesses Jumper Install in 8 Card Receptacle Spray Gun Card Figure 3 11 Seal and Jumper Installation Example Showing 8 Spray Gun S...

Page 46: ...corrupt the data on the cards and damage the cards CAUTION Never turn off console power without first shutting down the iControl 2 program and operating system Doing so could corrupt the system softwa...

Page 47: ...e system is shipped The touch screen calibration values are stored on the program card If installing a new program card that has never been used before there will be no calibration file on the card Th...

Page 48: ...tuds located in the upper right inside corner of the console back wall using the two M5 nuts 8 Install the new cover plate and gasket on top of the console using the M5 serrated nuts removed in step 4...

Page 49: ...remove the grille and filter A C UNIT GASKET SUPPLIED WITH A C UNIT TOP COVER PLATE MOUNTING HARDWARE SUPPLIED WITH A C UNIT COVER 2 SHOWN FROM BELOW GASKET GROUND STUDS AND FASTENERS TUBING TO FLOOR...

Page 50: ...A C UNIT A C UNIT POWER CORD CUSTOMER POWER CONDUIT WIRE 200 250 VAC 50 60Hz WIRING HARNESS INCLUDED WITH KIT 400W iCONTROL POWER SUPPLY L2 L1 GREEN YELLOW BLUE BROWN GREEN YELLOW BLACK RED Figure 3...

Page 51: ...power without first performing a program shutdown Doing so could corrupt the iControl 2 program and operating system on the program card Refer to Program Shutdown in the Configuration section of the...

Page 52: ...ata field contains illegal bits 111 Stuffing error Recessive bit not detected in 5 data bits 112 Other error Other errors not listed as Bit Stuff or Form 113 CAN Transmit Buffer overflow Host CAN inte...

Page 53: ...ed to trigger while in lockout page 4 9 Pump Controller 571 System heartbeat lost Check circuit board connections 572 5 24 volt power Check circuit board connections 573 Error writing to internal EEPR...

Page 54: ...on in pattern air flow control valve Clean valve as described in pump manifold manual 707 Powder high PWM Powder air flow more than commanded value Check output of flow regulator center regulator in p...

Page 55: ...descriptors exceeded Too many connections are open page 4 14 910 No permission to access serial or TCP port The program requesting the Ethernet resource does not have permission to do so page 4 14 911...

Page 56: ...otector The motor protector is open page 4 24 2004 Motion Controller The motion controller indicates a failure page 4 24 2005 Forward Contactor The forward contactor did not engage page 4 24 2006 Reve...

Page 57: ...4 2 CAN Network Messages Error Code Message Cause Correction 101 CAN bus fault detected Hardware error Check the CAN cable for shorts If the cable is good replace the CAN card 102 CAN receive buffer o...

Page 58: ...3 Micro amp feedback not detected Check the spray gun current with no parts in front of the spray gun If the current is 105 A check for a short circuit of the current feedback wires in the spray gun c...

Page 59: ...st fan is shut off 531 System heartbeat lost Check circuit board connections 532 5 24 volt power Check circuit board connections 533 Error writing to internal EEPROM Hardware error Replace card 534 Er...

Page 60: ...reen and clear all faults Replace the card if the malfunction cannot be corrected Status Green Flashing heartbeat when communicating properly with system If the status LED is not flashing make sure th...

Page 61: ...y Gun B Spray Gun A Figure 4 1 Spray Gun Control Card LEDs and Switches 1 Reset switch reboots the on board processor 2 Fault LED red 3 Status LED green 4 Spray Gun Limit B LED yellow 5 Spray Gun Limi...

Page 62: ...nal errors Re Zero Procedure See Figure 4 2 For each pump board that is being re zeroed 1 Disconnect the pattern air tubing controlled by the pump board from the output fittings on the rear panel of t...

Page 63: ...2022 Nordson Corporation 1609758 04 4 13 Troubleshooting Address Switch SW1 TEST Button Figure 4 2 Dual Pump Control Board...

Page 64: ...s lost while operating in Auto mode the machine will move to the Park position Check the Network Node Status screen If communication is lost the node icon should turn red If no nodes are red check the...

Page 65: ...ardware error Check PLC functions 927 Illegal Data Value exception response Programming error or remote hardware error Check PLC functions 928 Slave Device Failure exception response Programming error...

Page 66: ...Out Positioner Error Code Troubleshooting Error Code Message Meaning Correction 1001 E Stop Open Determine why E Stop button on system electrical control panel or a remote panel was pressed and corre...

Page 67: ...the controller if necessary 1005 Forward Contactor Auxiliary contact on the motor forward contactor or similar control circuitry did not operate when the in out positioner was commanded to move forwa...

Page 68: ...al or Auto 3100 Positioner Watchdog fault The positioner controller did not respond with a watchdog signal in 1 second Check the Ethernet cable connections and the positioner controller 4109 Clean cyc...

Page 69: ...ordson USA ColorMax system Disable action is applied by a remote system control panel keyswitch In the Disable position the keyswitch opens the disable input circuit at the in out positioner controlle...

Page 70: ...e Auto mode is selected The in out positioners can be operated manually while the booth fan is off In Out Positioner scanner not responding to parts passing by on the conveyor Conveyor encoder not sen...

Page 71: ...ve it again to the target position If the value is not large enough the in out positioner will over or under shoot its destination and then jump back to it called hunting A typical setting is 0 5 0 7...

Page 72: ...it zero position 2 Reverse the in out positioner slightly off the limit record the displayed position value and apply reference marks to the in out positioner and base 3 Manually move the in out posit...

Page 73: ...or Error Code Troubleshooting Error Code Message Correction 2001 E Stop Open Determine why E Stop button on system electrical control panel or remote panel was pressed and correct if necessary Reset E...

Page 74: ...controller if necessary 2005 Forward Contactor Auxiliary contact on the motor forward contactor or similar control circuitry did not operate when the in out positioner was commanded to move forward C...

Page 75: ...ay gun carriage Refer to reciprocator manual This fault must be reset from the iControl 2 Alarm screen 2101 Part size less than minimum Default or preset settings define a stroke length less than the...

Page 76: ...state for color change Reciprocator not in Auto mode Color change cycle cannot start unless reciprocator is in Auto mode Set reciprocator mode to Auto 3200 Reciprocator Watchdog fault The reciprocator...

Page 77: ...have not been completed Refer to Network Configuration and Reciprocator Configuration in the iControl 2 Operator Interface manual Make sure all required settings have been made and are correct Recipr...

Page 78: ...lt and sprocket Incorrect reciprocator speed controller parameters Speed controller parameters must be set to specified values in order to respond correctly to signals from reciprocator controller No...

Page 79: ...ith the keypad you can enter a number larger than the maximum but when you save your entry the value will be automatically reduced to the maximum value Condition Inconsistent lead and lag timing for a...

Page 80: ...will not be triggered Relays DIN rail The conveyor interlock relay LED lights when the conveyor is running The remote lockout relay LED is lit as long as it is receiving a signal lockout on The alarm...

Page 81: ...bration start the Program Shutdown procedure When the operating system shutdown prompt appears on the screen touch the Cancel button then touch the CAL button Follow the calibration instructions on th...

Page 82: ...f possible open the System Configuration screen and touch the Program Shutdown button When the operating system shutdown prompt appears on the screen touch the Cancel button then the CAL button If una...

Page 83: ...to wherever screen was touched or nothing happens buttons are touched or the touch screen cannot be calibrated then the touch screen has failed Replace the iControl 2 PC Temporary Fix Connect a USB mo...

Page 84: ...2022 Nordson Corporation 1609758 04 4 34 Troubleshooting...

Page 85: ...ock out power before opening the console to make repairs All repairs should be made by a qualified electrician Failure to observe this warning could result in personal injury or death Repair consists...

Page 86: ...to right Each card controls two spray guns the bottom receptacle is the odd spray gun number the top receptacle is the even spray gun number To remove a card disconnect the spray gun harness connector...

Page 87: ...fault LED on the card will light and a fault message will appear on the Alarm screen To reset the fault LED open the Alarm screen and touch the Clear All Faults button 1 2 3 4 5 6 Spray Gun Connector...

Page 88: ...n only be plugged in one way If the cables are not keyed replace them as soon as possible with keyed cables I O card replacements are shipped with a new cable The ribbon cables have a red or blue trac...

Page 89: ...iControl 2 system 2 Disconnect the video cable touch screen serial cable and power cable harness from the back of the old touch screen unit and set aside See Figure 5 3 3 Remove the mounting nuts 3 f...

Page 90: ...ch screen terminal block 4 as shown NOTE The touch screen is calibrated at the factory If changing the program card replacing the iControl 2 PC or having problems touching screen components accurately...

Page 91: ...09722 CONTROLLER Encore HD iControl 2 24 gun main console 1609723 CONTROLLER Encore HD iControl 2 26 gun main console 1609724 CONTROLLER Encore HD iControl 2 28 gun main console 1609725 CONTROLLER Enc...

Page 92: ...ROLLER Encore HD iControl 2 8 gun auxiliary console 1609745 CONTROLLER Encore HD iControl 2 10 gun auxiliary console 1609746 CONTROLLER Encore HD iControl 2 12 gun auxiliary console 1609747 CONTROLLER...

Page 93: ...PJ1 iControl 2 with pedestal 30 meter Aux to Pedestal 1602871 HARNESS part ID PD1 iControl 2 Main Console to part ID Junction Box E 1603103 CABLE AC power 10 meter auxiliary iControl F 1604310 CABLE i...

Page 94: ...the parts listed in this table Item Part Description Quantity Note 1 939122 SEAL conduit fitting blue AR 2 984526 NUT lock 1 2 in conduit AR 3 334800 PLUG 1 2 in Pipe 1 in hex AR 4 1609937 PLATE blank...

Page 95: ...2022 Nordson Corporation 1609758 04 6 5 Parts 1 1 1 4 2 3 2 3 2 3 Figure 6 1 Main and Auxiliary Console Parts Rear View 1 of 3...

Page 96: ...2 Rev 2 1 A E 16 KIT software iControl 1 A 16A MEMORY programmed iControl 1 16B 1034281 MEMORY Compact Flash blank for user data 1 17 334806 SWITCH round 2 position 90 degree 1 18 288806 CONTACT BLOC...

Page 97: ...2022 Nordson Corporation 1609758 04 6 7 Parts 5 6 7 10 8 9 12 13 14 15 16 17 19 20 7A 11 16A 16B 18 Figure 6 2 Main and Auxiliary Console Parts Internal Components 2 of 3...

Page 98: ...ard iControl 2 1 22 1609757 POWER SUPPLY DIN 115 230 Vac 24 Vdc 120 W 1 23 1609928 TERMINAL BLOCK AC DC convertor and fuse 1 23A FUSE 4A fast acting 250 V 5 x 2 2 23B FUSE 10A fast acting 250 V 2 24 3...

Page 99: ...SEMBLY module digital input iControl 2 pedestal 1 5 1602967 TERMINAL BLOCK pedestal iControl 2 1 6 CPU Arbor iControl 2 Rev 2 1 B 6A MEMORY programmed iControl 1 6B 1034281 MEMORY compact flash blank...

Page 100: ...ht receiver 18 in 3 4 in beam spacing 24 beam 339739 SENSOR light emitter 24 in 3 4 in beam spacing 32 beam 339740 SENSOR light receiver 24 in 3 4 in beam spacing 32 beam 339741 SENSOR light emitter 3...

Page 101: ...04 6 11 Parts Photocell and Scanner Cables Part Description Note SOW cable 18 4 321155 CABLE scanner 15 ft 321156 CABLE scanner 25 ft 321157 CABLE scanner 50 ft 343207 CABLE scanner rated 15 ft 34723...

Page 102: ...2022 Nordson Corporation 1609758 04 6 12 Parts...

Page 103: ...of the wiring diagrams and schematics Go to http emanuals nordson com for electronic version of the manual for Encore HD iControl 2 Integrated Control System manual Number Description 10015536 iContro...

Page 104: ...2022 Nordson Corporation 1609758 04 7 2 Drawings...

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Page 111: ...ble Directives 2006 42 EC Machinery Directive 2014 30 EU EMC Directive 2014 34 EU ATEX Directive Standards Used for Compliance EN ISO12100 2010 EN60204 1 2018 EN61000 6 3 2007 FM 7260 1996 EN60079 0 2...

Page 112: ...Systems Intended for use in Potentially Explosive Atmosphere Regulation 2016 Electromagnetic Compatibility Regulation 2016 Standards Used for Compliance EN ISO12100 2010 EN60204 1 2018 EN61000 6 3 200...

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