Nordson Encore HD iControl System Page 93 Hardware Manual Download

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CRITICAL

No revisions permitted without

approval of the proper agency.

ENCORE HD iCONTROL

THE FOLLOWING CONTROLLERS ARE SUITABLE FOR CLASS II,

DIV 2, GROUP F & G HAZARDOOUS (CLASSIFIED) LOCATIONS:
1602177 CONTROLLER,iCONTROL,ENCORE HD,4 GUN

1602178 CONTROLLER,iCONTROL,ENCORE HD,6 GUN

1602179 CONTROLLER,iCONTROL,ENCORE HD,8 GUN

1602180 CONTROLLER,iCONTROL,ENCORE HD,10 GUN

1602181 CONTROLLER,iCONTROL,ENCORE HD,12 GUN

1602182 CONTROLLER,iCONTROL,ENCORE HD,14 GUN

1602183 CONTROLLER,iCONTROL,ENCORE HD,16 GUN

1602184 CONTROLLER,iCONTROL,ENCORE HD,18 GUN

1602185 CONTROLLER,iCONTROL,ENCORE HD,20 GUN

1602186 CONTROLLER,iCONTROL,ENCORE HD,22 GUN

1602187 CONTROLLER,iCONTROL,ENCORE HD,24 GUN

1602188 CONTROLLER,iCONTROL,ENCORE HD,26 GUN

1602189 CONTROLLER,iCONTROL,ENCORE HD,28 GUN

1602190 CONTROLLER,iCONTROL,ENCORE HD,30 GUN

1602191 CONTROLLER,iCONTROL,ENCORE HD,32 GUN
THE ABOVE ARE APPROVED FOR USE WITH THE FOLLOWING

GUNS AND CABLES LOCATED IN A CLASS II, DIV 1, GROUP

F & G HAZARDOUS (CLASSIFIED) LOCATIONS:
GUNS:
1606969 GUN,BAR MT, ENCORE HD AUTO

1606970 GUN,TUBE MT,AUTO,5FT ENCORE HD

1606985 GUN,TUBE MT,AUTO,5FT PVC ENCORE HD

1606971 GUN,TUBE MT,AUTO,6FT ENCORE HD
OPTIONS:

1604084 EXTENSION,SPRAY,90 DEGREE,ENCORE
CABLES:
1097537 CABLE,AUTO,ENCORE,8M

1097539 CABLE,AUTO,ENCORE,12M

1097540 CABLE,AUTO,ENCORE,16M

1601344 CABLE,EXTENSION,ENCORE AUTO,4M

THIS DRAWING IS NORDSON PROPERTY,CONTAINS PROPRIETARY INFORMATION AND MUST BE RETURNED UPON REQUEST.
DO NOT CIRCULATE, REPRODUCE OR DIVULGE TO OTHER PARTIES WITHOUT WRITTEN CONSENT OF NORDSON.

NOTICE

10011656

FILE NAME

MATERIAL NO.

REVISION

SCALE

ALL DIMENSIONS IN

REF DWG,APPROVED EQUIPMENT,iCONTROL,ENCORE HD

CADD GENERATED DWG.

NORDSON CORPORATION

WESTLAKE, OH, U.S.A. 44145

DRAWN BY

CHECKED BY

EXCEPT AS NOTED

THIRD ANGLE
PROJECTION

X±0.8

X.X±0.25

MACHINED SURFACES

1.6

BREAK INSIDE/OUTSIDE CORNERS

0.1/0.8

THREAD LENGTH DIMENSIONS ARE

FULL THREAD

INTERPRET DRAWINGS PER ASME

Y14.5-2009

PERFECT FORM AT MMC REQUIRED

FOR INTERRELATED FEATURES

DESCRIPTION

DATE

APPROVED BY

RELEASE NO.

SIZE

MATERIAL NO.

REVISION

PE602969

10011656

1:5

SHEET

X.XX±0.13

RJF

Obsolete

Summary of Contents for Encore HD iControl System

Page 1: ...N CORPORATION AMHERST OHIO USA C APPROVED US FM 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 subject to change without notice Check http emanuals nordson com for the latest version O b s o l e t e ...

Page 2: ...erst 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 Nor...

Page 3: ...Change Record i Part 1603054 02 E 2015 Nordson Corporation Change Record Revision Date Change 01 03 13 Released 02 04 15 Removed part numbers from parts list O b s o l e t e ...

Page 4: ...Change Record ii Part 1603054 02 E 2015 Nordson Corporation O b s o l e t e ...

Page 5: ... 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 Addresse...

Page 6: ...ump 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 a...

Page 7: ... 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 O b s o l e t e ...

Page 8: ...Table of Contents vi Part 1603054 02 E 2015 Nordson Corporation O b s o l e t e ...

Page 9: ...ulations 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 S using incompatible materials S making unauthorized modifications S removing or bypassing safety gu...

Page 10: ... S To 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 S Do not smoke weld grind or use open flames where flammable materials a...

Page 11: ...otential 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 S Operators must maintain skin to handle contact between their hand and the gun handle t...

Page 12: ...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 O b s o l e t e ...

Page 13: ...ed 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 S 1056418 Operator Card for all versions S 1024758 and this manual An Encore HD iControl system console controls up to 32 automatic guns Figure 2 1 Prodigy iControl Console O b s o l e t e ...

Page 14: ...yor interlock relay S network interface box S feed 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 ...

Page 15: ...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 O b s o l e t e ...

Page 16: ... 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 th...

Page 17: ...unction 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 Encod...

Page 18: ...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 iContr...

Page 19: ... 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 Encor...

Page 20: ...UTPUT 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 ...

Page 21: ...ndustrial temperature rating for use in Embedded Systems Industrial flash has a rating of 2 000 000 write cycles and an increased temperature range to 85_C 185_F Cards that have been validated S SanDisk retail to 2 GB industrial to 1 GB S Toshiba retail to 2 GB S PNY retail to 2 GB S Dane Elec retail 512 MB S Kingston Technology retail to 4 GB S Smart Modular Technologies industrial to 1 GB S SMC ...

Page 22: ...System Overview 2 10 Part 1603054 02 E 2015 Nordson Corporation O b s o l e t e ...

Page 23: ...rofit and the equipment furnished by the customer Therefore this section provides 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 installed and wired and the system is powered up the operator interface is used to configure setup and operate the sy...

Page 24: ...al Gun Controllers Pump Control Cards 2nd Console Guns 1 32 AC Power CAN CAN Manual Gun J Box Figure 3 5 Typical System Diagram Hardware Installation Refer to the drawings furnished by Nordson application engineering for locations of the consoles junction boxes and other system devices Bolt the iControl console to the floor The photoeye junction box and analog scanner box if used are typically mou...

Page 25: ...E WHT BLUE A B A B A B A B A B A B A B A B WHT BLUE BLUE WHT BLUE BLUE Two Conductor Twisted Pair Shielded Cable Manual Gun J Box PE RED BLUE WHT BLUE BLACK BLUE WHT BLUE SHIELD WHT BLUE BLUE iControl Console 1 1 1 1 1 1 BLUE WHT BLUE BLUE WHT BLUE SHIELD BLUE WHT BLUE 1 CAN Network Termination Jumper Pins 1 2 on last card in chain Network Power Cable Last Pump Card in Last Pump Cabinet HDLV Pump ...

Page 26: ... Backplane Guns 1 16 SW1 1 SW1 2 Closed Closed Guns 1 16 Closed Open Gun 17 32 SW1 3 Closed End Open Continuous Figure 3 2 CAN Network Connections Console Addresses and Termination Manual Gun Controller Addresses The manual gun controller addresses are set through software Each controller must have a unique address Up to four manual guns can be included in a system Refer to the gun controller manu...

Page 27: ... the booth base if possible Refer to Grounding on page 3 7 for more information WARNING Consoles and all conductive equipment in the spray area MUST be connected to a true earth ground Mount the junction boxes and control panels to grounded stands or the booth base Connect the consoles to the booth base with the special flat braided cables provided Failure to observe this warning could result in d...

Page 28: ...GRAY GRAY 20K 240V 240V 240V 240V A1 A2 14 11 12 A1 A2 14 11 12 A1 A2 14 11 12 Remote Lockout 120V Alarm Conveyor Interlock 120V 20K YELLOW ORANGE YELLOW RED GRAY GRAY 20K 240V 240V 240V 240V A1 A2 14 11 12 A1 A2 14 11 12 A1 A2 14 11 12 Remote Lockout 240V Alarm Conveyor Interlock 240V 120V Relay Connections 240V Relay Connections Factory RED RED BLACK BROWN BLUE WHITE RED RED BLACK BROWN BLUE WHI...

Page 29: ...age until a fuse or circuit breaker interrupts the circuit The green yellow ground wires bundled with the AC input power cable are used only for PE grounding and their sole purpose is to protect personnel from a shock These ground wires do not protect against electrostatic discharge Electrostatic Grounding Electrostatic grounding protects electronic equipment from damage caused by electrostatic di...

Page 30: ...k to the controller through a ground braid and back to the spray gun through the gun driver board The current attracted to the booth is returned through the booth ground to the controller and back to the gun It is very important to provide a complete circuit for the gun current A break in the circuit conductors conveyor booth braided ground cables controller can cause voltage to build up on the co...

Page 31: ...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 welded base with the included self drilling screws An ESD grounding block kit is available for connecting the ground braids to the booth base The kit contains two 6 position grounding blocks fasteners terminals and 15 meters 50 feet of...

Page 32: ...it 2 BLK WHT 22 LO 11 Part ID bit 3 RED WHT 23 LO 12 Part ID bit 4 GRN WHT 0 LO 13 Part ID bit 5 BLU WHT 1 LO 14 Part ID bit 6 BLK RED 2 LO 15 Part ID bit 7 WHT RED 3 LO 16 Part ID bit 8 ORG RED 4 LO Trigger Bank 0 BLU RED 5 LO Trigger Bank 1 RED GRN 6 LO Trigger Bank Select Enable ORG GRN 7 LO 20 Encoder A BLK WHT RED 16 LO Spare WHT BLK RED 17 LO spare RED BLK WHT 18 LO Manual Lockout GRN BLK WH...

Page 33: ... Connections and Configuration Connect SO cable to the photoeyes and photoeye junction box terminal block as shown on the PEJB drawing Route the cables through the cord grips installed in the PEJB as shown Configure the photoeyes and set their sensitivity as shown on the PEJB drawing Scanner Cable Connections See Figure 3 6 The photoeye junction box and scanner junction boxes are shipped with the ...

Page 34: ...detect the width of the parts The scanners must be mounted with the cable ends oriented as shown If using dual scanners mount them so that they do not see the conveyor Connect the positioner scanner cables BSCE BSCR from the junction box to the scanners as shown If the system also has reciprocators then analog scanners are used to detect the part height and top and bottom edges Mount the scanners ...

Page 35: ...nnections Customer Supplied Part ID System Connections Refer to Table 3 2 Use the Part ID terminals on the PEJB to connect a customer supplied part ID system to the iControl console The 8 inputs are used based on the settings made in the Photoeye Configuration screen Refer to the iControl Operator Interface manual for configuration instructions Ethernet Network Gun Mover Control The Ethernet netwo...

Page 36: ...t connect any device to the Ethernet network that is not approved by Nordson Technical Support or Engineering iControl Console Main Electrical Control Panel Analog Scanner Controllers iControl System PLCs Switch VFDs Reciprocator or Oscillator Motor Positioner Motor Reciprocator or Oscillator Motor Positioner Motor Figure 3 8 Ethernet Network Gun Mover Control Typical System O b s o l e t e ...

Page 37: ... number of guns the fault LED on the card with only one gun connected will light NOTE The unused gun must be the highest even number gun For example if you have an 8 gun system then number 8 must be the unused gun The gun card receptacles are labeled on the circuit boards as A odd number gun and B even number gun Included in the bag with the console keys is a seal and jumper The jumper will disabl...

Page 38: ...ontrol program and operating system Doing so could corrupt the system software Refer to Program Shutdown in the iControl Operator Interface manual for the shutdown procedure See Figure 3 10 The CompactFlash card slots are on the back on the PC The top card 1 is the data card the bottom card 2 is the program card NOTE To remove a card simply pull it out of the slot 1 2 Figure 3 10 User Data and Pro...

Page 39: ...utomatically start the calibration procedure Follow the calibration instructions on the screen exactly using your finger to touch the targets When you have completed the calibration procedure touch the iControl button to start the iControl software Refer to Troubleshooting for a complete description of the calibration procedure and instructions on calibration System Upgrades Parts requirements for...

Page 40: ...Installation 3 18 Part 1603054 02 E 2015 Nordson Corporation O b s o l e t e ...

Page 41: ...odes and Alarm Messages Table 4 1 Error Codes and Messages Code Message Text Description Refer to Page NA Not currently applicable Code may differ on early software releases 10x CAN and Node State 101 CAN bus fault detected N A 4 6 102 CAN receive buffer overflow Host CAN interface receive too much data and could not process it quickly enough 4 6 103 Message timeout Remote CAN device did not respo...

Page 42: ... 4 7 305 Short circuit detected Multiplier drive circuit shorted 4 7 306 Internal hardware fault detected Internal DSP fault 4 8 308 Gun not detected Gun not connected to system 4 8 5xx Remote Device Node Electrostatic Node Gun Card 531 System Heartbeat lost Remove device lost heartbeat message 4 8 532 5 24 Volt power Remove device power detection failure 4 8 533 Error writing to internal EEPROM E...

Page 43: ...or EEPROM data not valid 4 11 70x Prodigy Pump Controller 701 Pattern servo fault The solenoid resistance was not detected or incorrect when the device was not triggered 4 11 702 Pump servo fault The solenoid resistance was not detected or incorrect when the device was not triggered 4 11 703 UNDEFINED ERROR1 4 11 704 UNDEFINED ERROR2 4 11 705 Powder low PWM Air flow less than commanded value 4 11 ...

Page 44: ...ailable 4 15 917 Checksum error Data packets were received with errors 4 15 918 Invalid frame error Data packets were received with errors 4 15 919 Invalid reply error Data packets were received with errors 4 15 920 Reply time out A reply to a request was not received in time 4 15 921 Modbus exception response An illegal Modbus command was detected 4 15 925 Illegal Function exception response An i...

Page 45: ...he reciprocator will attempt to stroke at the minimum length 4 25 2102 Lead gun not defined using gun 1 The lead gun on the reciprocator is not defined 4 25 2103 Trail gun not defined using gun 1 The trailing gun on the reciprocator is not defined 4 25 2104 Trail gun less than lead trail lead The trailing gun number is less than the lead gun number 4 25 2105 Pattern width not set using 12 inches 3...

Page 46: ...ta and could not process it quickly enough Reboot the system 103 Message timeout Remote CAN device did not respond to a direct request in the allotted time Check the gun card or iFlow card 104 Went offline Normal operational message The user will see this message if the booth exhaust fan is shut off which removes power from gun cards or if the gun card is disconnected or if the iFlow module is dis...

Page 47: ...E3 Micro amp feedback not detected Check the gun current with no parts in front of the gun If the current is 105 A check for a short circuit of the current feedback wires in the gun cable Unplug the cable from the gun and trigger the gun S If the fault stays E3 replace the cable S If the fault changes to E7 check the resistance of the multiplier as described in the gun manual 304 Open circuit dete...

Page 48: ... 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 Error reading to internal EEPROM Hardware error Replace card 535 Node address changed from last power up Saved address does not match current address Address switches were changed Informational message only 536 Internal data...

Page 49: ...on cannot be corrected Status Green Flashing heartbeat when communicating properly with system If the status LED is not flashing make sure the card is seated in the backplane Turn console power off and on Replace the card if the other gun control cards have heartbeats Foldback B even numbered gun Yellow Lights if over current protection circuit triggered due to high current draw from gun drive cir...

Page 50: ... Gun B 1 2 3 4 5 6 7 Figure 4 1 Gun Control Card LEDs and Switches 1 Reset switch reboots the on board processor 2 Fault LED red 3 Status LED green 4 Foldback B LED yellow 5 Foldback A LED yellow 6 Power LED green 7 SW2 2 position dipswitch for future use O b s o l e t e ...

Page 51: ...Pattern servo fault The solenoid resistance was not detected or incorrect when the device was not triggered When the solenoid is not energized the resistance of the solenoid is checked by the system These faults are generated if no resistance is detected or the correct resistance is not detected Check the proportional valve wiring connections Check the solenoid operation Replace the valve if the s...

Page 52: ...ero procedure S Make sure the air pressure being supplied to the pump cabinet is higher than the minimum 5 86 bar 85 psi S Each pump circuit board in the pump cabinet controls two pumps and the pattern air for two spray guns Make sure no air is flowing through the pumps around the pump control manifold gaskets or from around any of the solenoid valves on the manifold Re zeroing boards when leaks a...

Page 53: ...ait 5 seconds then turn the power back on 9 Remove the plugs from the pattern air output fittings and re connect the pattern air tubing 10 At the iControl console check each gun control screen that was previously indicating air flow when the gun was off No air flow should be indicated Address Switch SW1 TEST Button Figure 4 2 Dual HDLV Pump Control Board O b s o l e t e ...

Page 54: ...ne 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 Network Node Configuration screen to find the device associated with the faulted node IP address If multiple node faults are displayed Check the electrical power supply to all faulted nodes Check the Ethernet switch in the network interface box...

Page 55: ...r to manufacturer manual for troubleshooting 926 Illegal Data Address exception response Programming error or remote hardware error Check node functions Refer to manufacturer manual for troubleshooting 927 Illegal Data Value exception response Programming error or remote hardware error Check node functions Refer to manufacturer manual for troubleshooting 928 Slave Device Failure exception response...

Page 56: ...sitioner Error Code Troubleshooting Table 4 7 In Out Positioner Error Code Troubleshooting Error Code Message Correction 1001 E Stop Open E Stop button pressed Determine why E Stop button was pressed and correct if necessary Reset E stop button when clear to do so 1002 Encoder Failure Fault In out positioner not moving Mechanical motor or motor controller failure Change in out positioner operating...

Page 57: ...contact on the motor forward contactor did not close when the in out positioner was commanded to move forward Check forward contactor for proper operation Repair or replace contactor as needed Check control circuit and devices that energize the contactor for proper operation Repair or replace components as needed This fault must be reset from the iControl alarm screen 1006 Reverse Contactor Fault ...

Page 58: ...nual 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 cycle aborted Arch clean operation waiting on Park release Euro color change only During a SpeedKing booth cleaning cycle an in out positioner has moved off its reverse limit switch or the limit switch...

Page 59: ... display on iControl screens If Nordson 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 controller No corrective action is required unless the keyswitch Normal position does not allow motion Refer to your system drawings for circuit details If not Nordson USA Colo...

Page 60: ...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 sending pulses to the iControl system Refer to Photoeye Encoder and Conveyor Interlock Troubleshooting on page 4 30 In Out Positioner scanners not detecting parts Check scanner input values on the Input Status screen R...

Page 61: ...ttempt to move to the target position If this value is not large enough the in out positioner will hunt for the position causing unwanted motion A typical setting is 0 5 0 7 inches depending on the in out positioner speed setting In Out Positioner actual travel distance does not match value shown on iControl screens In Out Positioner position calibration not completed or in out positioner forward ...

Page 62: ...ion 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 positioner in reverse almost but not all the way to the reverse limit the greater the distance the more accurate the calculated resolution will be 4 Use your reference marks to measure the distance moved and compare th...

Page 63: ... for more information Reciprocator Error Code Troubleshooting Table 4 9 Reciprocator Error Code Troubleshooting Error Code Message Correction 2001 E Stop Open E Stop button pressed Determine why E Stop button was pressed and correct if necessary Reset E stop button when clear to do so 2002 Encoder Failure Fault Reciprocator not moving Mechanical motor or motor VFD failure Change reciprocator opera...

Page 64: ... Contactor Auxiliary contact on the motor forward contactor did not close when the reciprocator was commanded to move up Check up contactor for proper operation Repair or replace contactor as needed Check control circuit and devices that energize the contactor for proper operation Repair or replace components as needed This fault must be reset from the iControl alarm screen 2006 Down Contactor Fau...

Page 65: ...e guns and gun carriage Refer to reciprocator manual This fault must be reset from the iControl Alarm screen 2101 Part size less than minimum Default or preset settings define a stroke length less than the minimum 4 in Change default or preset settings or if parts are small consider turning off reciprocators for batch 2102 Lead gun not defined using gun 1 Lead gun number not entered in reciprocato...

Page 66: ...Auto 3200 Reciprocator Watchdog fault The reciprocator controller did not respond with a watchdog signal in 1 second Check the Ethernet cable connections and the reciprocator controller Other Reciprocator Troubleshooting Table 4 10 Other Reciprocator Troubleshooting Problem Cause Correction No movement of reciprocator in response to move command A fault has occurred preventing operation Check the ...

Page 67: ...n and Reciprocator Configuration in the iControl Operator Interface manual Make sure all required settings have been made and are correct Refer to your system electrical drawings and make sure all connections have been made correctly Reciprocator changes direction before or after the programmed turn around position in Auto mode Turn around offset not set correctly An error close to 1 2 in of the s...

Page 68: ...and sprocket Incorrect reciprocator VFD parameters VFD parameters must be set to specified values in order to respond correctly to signals from reciprocator controller Contact Nordson technical support No reciprocator response when Auto mode selected Refer to condition No reciprocator response when Auto mode selected Auto cycle delay in progress A 5 second delay occurs when Auto mode is selected D...

Page 69: ...to Compact Flash adapter and PC Replace ribbon cable if necessary Standard 40 pin IDE cable not available from Nordson Condition Pickoff value is reset to smaller number after entry The maximum pickoff length is 4096 inches 104038 4 mm With 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 I...

Page 70: ...ail 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 relay LED stays lit until an alarm occurs then goes out All 1 24 Input LEDs should indicate as described above If none of the LEDs turn on check the following screens Zone and Part ID Inputs Open the Input Status screen Inputs should ...

Page 71: ...alibration start the Program Shutdown procedure When the operating system shutdown prompt appears on the screen touch the Cancel button then touch the CAL button Problems During Calibration If you do not follow the calibration instructions exactly You will not be able to touch the center Completion button and exit the calibration procedure If this happens stop and wait until the procedure times ou...

Page 72: ...n 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 touch the CAL button If you cannot touch any buttons on the screen then you will have to cycle console power and try again 5 When the calibration procedure starts USE YOUR FINGER NOT THE MOUSE to touch the calibration targets following...

Page 73: ...ix Shut off console power and connect a VGA monitor keyboard and mouse to the PC ports Turn console power on If the boot screens and iControl screens display on the VGA monitor you can use the mouse to click on buttons and select fields and use the keyboard to enter and change values Rotary Dial Troubleshooting If rotating the dial on the keypad panel does not change the selected data field value ...

Page 74: ...cable into the termination module connected to the cable run This provides you with two RJ45 male connectors on the cable run to connect to the test unit 2 Plug the other end of the patch cable into the remote unit 3 Plug the RJ45 male connector at the network interface end of the cable run into the main unit of the cable tester 4 Turn the main unit on 5 Watch the cable pair LEDs on the remote uni...

Page 75: ...nts and replacing them with new ones There are no components inside the cabinet that can be repaired by the customer Refer to the wiring diagrams in Section 7 for connections WARNING Whenever replacing a component that interfaces with the exterior of the cabinet such as a gun harness receptacle make sure that the dust tight intergrity of the cabinet is intact by installing the correct gaskets and ...

Page 76: ... the card is the odd gun number the top receptacle the even gun number To remove a card unplug the gun harnesses from the card receptacles 3 and 4 pull down the locking tab 5 then pull the card out of the card cage To install a new card slide the card into the slots in the card cage and seat the card s finger board firmly into the connector slot on the backplane 6 Push the locking tab up to lock t...

Page 77: ... the PC Use it to connect the PC to the digital input module CAUTION Plugging in the ribbon cable the wrong way may damage the cable or the circuit board when power is applied Reversing the ribbon cable polarity of the cable from the iControl computer to the I O card will cause catastrophic failure of the iControl unit Make sure the cable is connected correctly The ribbon cables are keyed so that ...

Page 78: ...ration Ribbon Cable Connections PC I O Board Ribbon Cable Key Pin 1 Mark Arrow PC End Pin 1 Mark Arrow I O Board End Connection Key Notch Connection Key Notch Red Conductor Pin 1 Figure 5 4 Computer I O Board Ribbon Cable Connections O b s o l e t e ...

Page 79: ...troduction For parts and technical support call the Nordson Industrial Coating Systems Customer Support Center or contact your local Nordson representative Customer Support Center Telephone 800 433 9319 Facsimile 888 229 4580 Email finishing_csc nordson com O b s o l e t e ...

Page 80: ...er iControl Encore HD 12 gun 1602182 Controller iControl Encore HD 14 gun 1602183 Controller iControl Encore HD 16 gun 1602184 Controller iControl Encore HD 18 gun 1602185 Controller iControl Encore HD 20 gun 1602186 Controller iControl Encore HD 22 gun 1602187 Controller iControl Encore HD 24 gun 1602188 Controller iControl Encore HD 26 gun 1602189 Controller iControl Encore HD 28 gun 1602190 Con...

Page 81: ... 3 1105343 S CARD I O PC104 1 5 1000595 CONTACT BLOCK 1 N O and 1 N C contact 1 6 1000594 SWITCH keylock 3 position 1 7 1032267 PANEL keypad iControl 1 8 1100775 MODULE 24 channel opto isolated 1 4 S CABLE IDE 80 conductor 1 9 1107146 JUMPER comb type 12 pole 10 mm AR A NS 1055881 CABLE CAT5 Ethernet T568B colors 30 ft 1 11 1034281 MEMORY Compact Flash blank for user data 1 B C 12 MEMORY programme...

Page 82: ...Parts 6 4 Part 1603054 02 E 2015 Nordson Corporation 6 5 3 2 7 9 8 14 13 12 11 4 1 Figure 6 5 Console Parts 1 of 4 PC shown without cover O b s o l e t e ...

Page 83: ...RELAY 24VDC 250V 6A DIN MT 1 18 939683 FUSE 6 30 fast acting 250V 5 x 2 4 19 939306 FUSE 3 15 fast acting 250V 5x20 2 20 320586 RESISTOR MF 20K 1W 5 AXL 2 21 334805 FILTER line RFI power 10A 2 Continued 21 20 L2 L2 L1 L1 L2 L1 240V 240V PE 240V 240V 14 11 12 A1 A2 14 11 12 14 11 12 L2 L2 L1 L1 L2 L1 240V 240V PE 240V 240V A1 A2 14 11 12 A1 A2 14 11 12 A1 A2 14 11 12 19 18 18 17 16 Figure 6 6 Conso...

Page 84: ...gun ID odd number AR B 24 1098442 POWER SUPPLY 400 watt 24V 12V 5V 5 slot 2 NOTE A One card controls the electrostatics for 2 automatic spray guns B Use to prevent fault LED from lighting when odd number of guns are connected Plug into gun card receptacle in place of receptacle harness for unused receptacle One jumper is shipped with each console AR As Required Continued 1 1 1 1 23 22 24 23A Figur...

Page 85: ... A 27A 1023695 SEAL bulkhead 7 8 16 thread AR B 28 984526 NUT lock 1 2 in conduit AR 29 939122 SEAL conduit fitting 1 2 in AR 30 334800 PLUG 1 2 in AR NOTE A One receptacle is required for each automatic spray gun B Use to cap unused receptacles One seal is shipped with each console AR As Required 18 28 29 30 28 27 29 27A Figure 6 8 Console Parts 4 of 4 O b s o l e t e ...

Page 86: ...Control Ethernet Components Part Description Note 1058222 CABLE CAT 5 Ethernet T568B colors 100 ft A 1058223 CABLE CAT 5 Ethernet T568B colors 300 ft A 1058224 MODULE termination CAT 5 T568B colors NOTE A Cables have male connectors at each end Refer to Section 3 Installation for use Conveyor Encoder Part Description Note 1074261 ENCODER 24 PPR w cable CAN Cable Part Description Note 1057592 JACKE...

Page 87: ...er 30 in 3 4 in beam spacing 40 beam 339742 SENSOR light receiver 30 in 3 4 in beam spacing 40 beam 339743 SENSOR light emitter 36 in 3 4 in beam spacing 48 beam 339744 SENSOR light receiver 36 in 3 4 in beam spacing 48 beam 339745 SENSOR light emitter 42 in 3 4 in beam spacing 56 beam 339746 SENSOR light receiver 42 in 3 4 in beam spacing 56 beam 339747 SENSOR light emitter 48 in 3 4 in beam spac...

Page 88: ...Parts 6 10 Part 1603054 02 E 2015 Nordson Corporation O b s o l e t e ...

Page 89: ...Wiring Diagrams 7 1 Part 1603054 02 E 2015 Nordson Corporation Section 7 Wiring Diagrams O b s o l e t e ...

Page 90: ...Wiring Diagrams 7 2 Part 1603054 02 E 2015 Nordson Corporation O b s o l e t e ...

Page 91: ... for Compliance EN ISO12100 2010 EN60204 1 2006 EN61000 6 3 2007 FM 7260 1996 EN60079 0 2013 EN50050 2 2013 EN61000 6 2 2005 EN60079 31 2014 EN50177 2009 EN55011 2009 Type of Protection Ambient Temperature 15ºC to 40ºC Ex II 2 D 2mJ Auto Applicators Ex II 2 D Main Console and Auxiliary Console Controllers Ex II 2 3 D Optional Pedestal ATEX Product Certificates FM13ATEX0006X Applicators Norwood Mas...

Page 92: ...O b s o l e t e ...

Page 93: ...FIED LOCATIONS GUNS 1606969 GUN BAR MT ENCORE HD AUTO 1606970 GUN TUBE MT AUTO 5FT ENCORE HD 1606985 GUN TUBE MT AUTO 5FT PVC ENCORE HD 1606971 GUN TUBE MT AUTO 6FT ENCORE HD OPTIONS 1604084 EXTENSION SPRAY 90 DEGREE ENCORE CABLES 1097537 CABLE AUTO ENCORE 8M 1097539 CABLE AUTO ENCORE 12M 1097540 CABLE AUTO ENCORE 16M 1601344 CABLE EXTENSION ENCORE AUTO 4M 8 A 7 6 5 THIS DRAWING IS NORDSON PROPERT...

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