Nordson Encore iControl 2 Configuration, Preset Setup, Operation Download Page 1

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iControl

Operator Interface

Configuration, Preset Setup, Operation

Customer Product Manual

Part 1056418-07

Issued 9/19

NORDSON CORPORATION

•

AMHERST, OHIO

•

USA

APPROVED

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.

Summary of Contents for Encore iControl 2

Page 1: ...19 NORDSON 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 repre...

Page 2: ...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 translat...

Page 3: ...iguration 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 Co...

Page 4: ...rsions 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...

Page 5: ...et 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...

Page 6: ...cons 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...

Page 7: ...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...

Page 8: ...Table of Contents vi Part 1056418 07 E 2019 Nordson Corporation...

Page 9: ...t 1056418 07 E 2019 Nordson Corporation 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 Administr...

Page 10: ...Change Record viii Part 1056418 07 E 2019 Nordson Corporation...

Page 11: ...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 car...

Page 12: ...tem 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 Shutd...

Page 13: ...witch has three positions S Ready Run system conveyor on signal is required S Lockout Use to shut off guns in out positioners and reciprocators S Conveyor Bypass Use to trigger guns without a conveyor...

Page 14: ...m 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...

Page 15: ...th 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 u...

Page 16: ...epresentatives 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 ac...

Page 17: ...them out when the timer runs out Security Configuration See Figure 2 1 Touch the Configure button to open the Security Configuration screen 4 1 2 3 13 12 11 10 9 8 7 5 6 Create Edit User Select Exist...

Page 18: ...ser 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 desir...

Page 19: ...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 Percen...

Page 20: ...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 A...

Page 21: ...ation 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...

Page 22: ...twork Configure Gun Pickoffs Yes Yes Yes No No No Configure Reciprocators Does system have positioners reciprocators analog scanners Will system use automatic triggering or gun positioning Configure Z...

Page 23: ...m Configuration tasks in the order shown in the Configuration Flowchart on page 3 2 Positioners Network Units Versions Encoder Pickoffs Part ID Guns User Data Backup Shutdown Reciprocators Prodigy Enc...

Page 24: ...the rest of the system configuration NOTE If the number of guns per console is not set values set in the configuration are not retained after the system is restarted This screen is also used to select...

Page 25: ...at preset use fast mode NOTE You cannot have a mix of version 1 and version 2 pump firmware in your system an alarm will occur if a mix of version 1 and 2 is detected Spectrum HD Select Spectrum HD if...

Page 26: ...e correct part number on the Guns Input Card Configuration screen S When the AX 754 card is installed and selected the Conveyor Indicator will light when the interlock is connected and the conveyor is...

Page 27: ...the Shutdown button Changing the flow limit does not require a system restart To restart the system 1 Touch the Shutdown button 2 A dialog box is displayed with the following choices S Logout End Phot...

Page 28: ...t of a gun it is triggered on and off Photoeyes or scanners light curtains are used to detect both the length of the parts and the zones the part occupies Zone Configuration Digital Zone Filter Zone C...

Page 29: ...cupies only zones 5 8 so only the guns assigned to those zones are triggered on NOTE Part 3 is hung so that the hangers occupy zones 1 4 Normally this could trigger on the spray guns assigned to those...

Page 30: ...analog signal for zone detection and the bottom up signal for reciprocator control Each zone is measured from the top of the scanner so a part automatically occupies all the zones from the bottom edge...

Page 31: ...ive filter value Part length is reduced by subtracting the filter value from the leading edge Use to prevent hanger detection hanger skip For example for hangers 1 inch wide a 1 inch zone filter reduc...

Page 32: ...he Analog Zone Scanner screen opens DIM Configure Zones Auto Zero 2 3 4 5 6 7 8 1 8 16 24 32 40 48 56 72 Zones Zone Height 032 Figure 3 9 Configuring Analog Scanners for Zone Detection 2 For each zone...

Page 33: ...uns immediately upon the change in state of a bit or series of bits In this mode the iControl console acts like a simple gun control console without the need for a conveyor encoder or zone photoeyes o...

Page 34: ...the part ID The part ID inputs must receive the part ID signal before the zone photoeyes or scanners detect the part If using part ID flags position the photoeyes or scanners S in the same vertical pl...

Page 35: ...part ID sensors to detect closed slots in a part flag The highest numbered photoeye detecting a closed slot determines the part ID number Slot 5 is closed so part ID 5 is detected and preset 5 is loa...

Page 36: ...The filter prevents the reading a false part ID from the solid edges of a part flag or other objects such as parts or hangers The filter value must always be positive The following example illustrate...

Page 37: ...ck parts A resolution of 1 0 inch limits the conveyor speed to 50 ft min 10 Hz a resolution of 0 100 inch limits the speed to 10 ft min Encoder Configuration and Clock Option Calculate Resolution Ente...

Page 38: ...nd x the next even multiple of 25 milliseconds encoder resolution For example 1 Convert 18 inches minute to inches second 18 x 12 60 3 6 ips 2 Convert to seconds per inch 1 3 6 0 277 or 277 millisecon...

Page 39: ...r and reset the counter to zero in Screen Box 2 The conveyor must be moving to reset the counter but the part must not move in front of the zone photoeyes or scanner before the counter is reset S Put...

Page 40: ...pickoff 0 040 x 100 4 Use the following procedure to adjust the resolution setting You may need to adjust the encoder mechanics also 1 Set the pickoff page 3 21 for one of the guns mounted farthest f...

Page 41: ...Pickoff Configuration Pickoffs The pickoff is the distance from the zone photoeyes or scanners to each gun Enter pickoffs for each of your guns To use the keypad to enter large numbers first touch th...

Page 42: ...ven if the trailing edge of the previous part has not been reached or lag of the previous part has not been completed NOTE This rule may cause erratic triggering For example the new preset may cause g...

Page 43: ...Spraying Here Lag Lead Lag Lead Direction of Travel Figure 3 20 Lag Priority Triggering Rule Split Priority This rule mandates that if the lead of the next part overlaps the lag of the previous part t...

Page 44: ...gurations The purge kits must be field installed in the consoles Purge kits are shipped with installation instructions The settings on this screen are used for automatic purging Set the nozzle purge m...

Page 45: ...before nozzle purging is activated Use the purge delay setting with a restricted spray or perfect pickoff 0 or negative lag settings where the coating could be ruined if purging starts too soon With...

Page 46: ...guns 17 32 2 2 dual 4 banks L1 and L2 for guns 1 16 R1 and R2 for guns 17 32 For example if you have two consoles with a dual purge kit in each then you can set the number of banks to 4 and split up t...

Page 47: ...d and enabled It works as follows S When the spray guns are triggered off the atomizing air flow changes to the purge setting and flows until the purge timer expires S If the guns are triggered on for...

Page 48: ...e and atomizing air flow to the preset flow settings over the specified time It starts automatically when the spray guns are triggered on NOTE With soft start the powder flow takes longer to reach the...

Page 49: ...stages in the Spectrum HD purge sequence Purge Duration 1 10 sec Number of Pulses 0 99 Pulse On 0 1 1 00 secs Pulse Off 0 1 1 00 secs Gun Purge Siphon Purge Pulse Cycle Purge Duration 1 10 sec Number...

Page 50: ...the panel are the pump control board and manifold On each pump manifold is a label with Pump Flow and Pattern Flow A B and C calibration constants which must be entered into the Pump Calibration scre...

Page 51: ...up and any changes made since the last backup will be lost NOTE Approved cards are SanDisk Toshiba PNY and Memorex 128 Mb minimum CompactFlash cards Do not use unapproved cards For more information co...

Page 52: ...the new card Store the original card in a safe place away from magnetic fields If the card has not been formatted or was formatted by an earlier version of the iControl software the iControl system f...

Page 53: ...uires a reboot S shut down the iControl program and operating system before you turn off power to the console CAUTION Do not turn off console power without first performing a complete shutdown Repeate...

Page 54: ...e iControl program S Touch Cancel to close the dialog box and use the operating system desktop utilities NOTE The shutdown procedures force all recently changed data to be written to disk The data in...

Page 55: ...creen backlights are off the screen will not turn back on If this happens you must cycle console power to restart the system Instruct all operators on the operation of the screen saver The power saver...

Page 56: ...o not follow the calibration instructions exactly you will not be able to touch the center Completion or Accept button and exit the calibration procedure If this happens stop and wait until the proced...

Page 57: ...ntal 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 Reciprocator Configuration 4 18 Operating Mod...

Page 58: ...s are required create positioner and reciprocator presets as described in Sections 6 and 7 of this manual System Configuration Screen Touch the Configure button on the Main screen button bar to open t...

Page 59: ...systems Network Status Functions Use the Network Status screen to check the status of the Ethernet network and the CAN network and to access the Node and Host Configuration screens The Node icons on...

Page 60: ...oth 192 162 1 1 2nd booth 192 162 1 2 and so on The Mask should always be set to 255 255 255 0 NOTE Newer versions of the software provide auto addressing to ensure address conflicts are handled corre...

Page 61: ...4 and reciprocator 4 RC1_RC2 reciprocators 1 and 2 PE scanners RC3_RC4 reciprocators 3 and 4 Configure the positioners first always entering them in numerical order If the system has reciprocators bu...

Page 62: ...ork has a unique MAC address The address is on the manufacturer label attached to the FieldBus couplers or controllers Enter this number into the MAC address fields TCP IP Address Each node must have...

Page 63: ...iguration 4 7 Part 1056418 07 E 2019 Nordson Corporation 3 4 1 2 3 4 GP1_RC1 GP2_RC2 GP3_RC3 GP4_RC4 Send IP Address Save Login 10 11 GP1_RC1 GP2_RC2 MAC ADDRESS TCP IP ADDRESS MACHINE TYPE Figure 4 4...

Page 64: ...tioner Figure 4 5 Positioner Configuration Screen 1 Mode Indicator 2 Positioner Orientation 3 Auto Mode 4 Manual Mode 5 Off Mode 6 Positioner Selector 7 Off Lock 8 Pickoff 9 Keypad 10 Jog Buttons 11 G...

Page 65: ...disables the controls on the Positioner Control screen Lockout Override Overrides the keyswitch lockout so that the positioners can be moved manually while the system is locked out Actual Position Ac...

Page 66: ...table describes the standard positioner configuration settings Item numbers in parenthesis correspond to the item numbers in Figure 4 5 These settings apply to both horizontal or vertical positioners...

Page 67: ...than the distance from the forward limit switch to the reverse limit switch Retract Position 14 Position within the positioner range of travel measured from the forward limit switch This position is...

Page 68: ...ng a plumb bob from the conveyor centerline 2 Move the in out positioner to the forward limit switch 3 Position the guns on the stand oscillator or reciprocator so that the gun tips are the desired di...

Page 69: ...om the floor at full up The topmost beam LBB of the scanner is 108 inches from the floor The gun to conveyor centerline value is 108 65 43 Top Down positioner The guns are 85 inches from the floor at...

Page 70: ...void collisions between guns and parts NOTE To prevent gun part collisions all move settings must take into account the part dimensions and the conveyor and positioner speed Minimum and Default Move S...

Page 71: ...sitioner moves the guns to 10 inches from the part Figure 4 7 8 in Conveyor Centerline Lead 4 in Default Gun to Part Wait Position Figure 4 7 Part at Lead Move Back Until Guns are 10 in From Part Top...

Page 72: ...tion if the switch is contacted first Conveyor Centerline Lag 4 in Default Gun to Part Wait Position Figure 4 9 Part at Lag Move Forward to Default Gun to Part Distance Top View Lancing Default Moves...

Page 73: ...10 inch gun to part distance Conveyor Centerline Retract Position Wait Position Spray Position Figure 4 11 Part in Front of Guns Gun to Part Distance Maintained Top View 3 Part at Lag When the traili...

Page 74: ...on Screen 1 Mode Indicator 2 Reciprocator Selector 3 Mode Buttons Off Manual Auto 4 Lock in Off Mode 5 Select Side of Booth 6 Open Keypad 7 Jog Up Down 8 Bottom Soft Limit 9 Top Soft Limit 10 Current...

Page 75: ...n If reciprocator controller power is cycled the reciprocator must be homed When homed the reciprocator should move slowly to the top limit switch and then stop approximately 1 inch below the top limi...

Page 76: ...ator overtravel at the set Turn Around points 1 Touch the Home button to home the reciprocator When home is completed move the reciprocator carriage down by hand until the current position 10 Fig 4 13...

Page 77: ...Clean Position 21 This is the position that you want the reciprocator to move to S when the Park button is touched S when a color change sequence is started application specific consult with your Nor...

Page 78: ...nization mode is selected then the reciprocator speed is calculated using the conveyor speed stroke length number of laps number of guns and pattern width Without synchronization the reciprocator spee...

Page 79: ...are the distances above and below the part edge to trigger the guns on and off on the downstroke and upstroke They are similar to lead and lag settings S Positive trigger points extend the spray patt...

Page 80: ...n the Oscillator mode Set the Fixed mode turnaround points to set the stroke length Any trigger point settings are ignored The spray guns are triggered on and off by the Spray Preset lead and lag sett...

Page 81: ...rt edge NOTE These settings can be modified from the Reciprocator Control screens which are accessible from the Main screen refer to Section 8 The Control screens also provide access to the Lap Calcul...

Page 82: ...ust Control screen shown in Figure 4 22 When the percent adjust function is enabled the button is green This function changes flow rate and atomizing air by percentages as the stroke length increases...

Page 83: ...Gun Mover Configuration 4 27 Part 1056418 07 E 2019 Nordson Corporation Enable Stroke Length Flow Rate Air Atomizing Air Stroke Length Flow Rate Air Atomizing Air Figure 4 22 Air Flow Percent Adjust C...

Page 84: ...st systems one or two horizontally mounted scanners are used to detect part width for horizontal in out positioners while a vertically mounted scanner is used to detect the part height for reciprocato...

Page 85: ...ration screen Cable end orientation is important because of the way the scanner signal is read NOTE The scanner controller must be configured to ignore the conveyor Scanner controllers are typically p...

Page 86: ...engths B Distance from last scanner beam end of scanner opposite cable end to the conveyor centerline B A A Figure 4 25 Dual Scanner Configuration for In Out Positioners Vertical Scanner Configuration...

Page 87: ...Use the vertical offset for reciprocators only For vertical up down positioners set the vertical offset to 0 See Figure 4 27 The Vertical Offset should be positive if the 0 channel of the scanner top...

Page 88: ...movement when no parts are in the booth Since the setting of the scanner resolution takes care of most error voltage in the system this procedure is used in extremely noisy environments When the syste...

Page 89: ...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 Rest...

Page 90: ...to other presets for the same gun and to presets for other guns The Preset Table screen allows you to view and set preset settings for all guns in the system one preset at a time in a table format Us...

Page 91: ...this screen offline only S To scroll the screen touch and drag the horizontal and vertical scroll bars 6 or touch the scroll bar arrows S To enter a value in a data field touch the field to select it...

Page 92: ...5 3 Spray Gun Control Screen Standard Guns 1 Gun number 2 Preset number and name 3 Copy All 4 Keypad 5 Save 6 Scroll bars 7 Copy All selection Preset Number and Name See Figure 5 4 Use the Preset Nam...

Page 93: ...ameter of the air tubing the powder and other variables 1 To set air flows touch a flow button then use the slider bar or rotary dial Only one setting can be made at a time 2 When all guns are set up...

Page 94: ...51 5 4 62 2 75 3 34 48 5 4 62 3 75 4 00 58 0 5 04 3 00 3 72 54 0 5 04 3 00 4 34 63 0 5 52 3 25 4 07 59 0 5 22 3 10 4 48 65 0 5 64 3 35 4 21 61 0 Table 5 2 Pressure to Flow Conversion Table 8 mm Tubing...

Page 95: ...ange is 2 55 10 2 M3 HR minimum 0 17 M3 HR increments or 1 5 6 0 SCFM minimum 0 1 SCFM increments Powder velocity is inversely related to transfer efficiency the higher the velocity the lower the tran...

Page 96: ...n Total Flow setting each increase in Flow Air increases powder flow NOTE These settings are affected by system variables such as powder characteristics tubing sizes and types spray gun type and other...

Page 97: ...67 50 5 10 r 54 5 52 57 5 95 60 6 37 63 6 80 65 7 22 67 7 65 68 8 07 70 8 50 1 9 2 97 22 3 82 30 4 24 36 4 67 42 5 09 46 5 52 50 5 94 53 6 37 56 6 79 59 7 22 61 7 64 63 8 07 65 8 49 67 8 92 2 3 3 40...

Page 98: ...2 50 45 2 75 50 3 00 54 3 25 57 3 50 60 3 75 63 4 00 65 4 25 67 4 50 68 4 75 70 5 00 28 1 75 22 2 25 30 2 50 36 2 75 r 42 3 00 46 3 25 50 3 50 53 3 75 56 4 00 59 4 25 61 4 50 63 4 75 65 5 00 67 5 25 3...

Page 99: ...umps smaller quantities of powder at a faster rate providing a more uniform flow This feature can also be used with problem powders that are hard to fluidize as it keeps the powder moving through the...

Page 100: ...le Screen Electrostatic Settings For Versa Spray Sure Coat Prodigy Encore and Encore HD guns you can set kV AFC or Select Charge mode These settings are mutually exclusive except for Select Coat Mode...

Page 101: ...t close range For Tribomatic guns use AFC to set the minimum current feedback level If the current feedback falls below this level then the powder is not receiving the expected electrostatic charge Th...

Page 102: ...oating inside boxes or other deep cavities Low kV and current coats the front edges of the cavity and high kV and current coats the back of the cavity Mode 4 User Programmable This mode allows you to...

Page 103: ...pray guns BEFORE the leading edge reaches them Extended Spray S A negative lead value turns on the spray guns AFTER the leading edge passes them Restricted Spray Lag Distance from the spray guns to th...

Page 104: ...n Lead 0 Gun On Lag 0 Gun Off Figure 5 12 Perfect Pickoff Extended Spray Example Use extended spray to wrap powder around the leading and trailing edges of parts See Figure 5 13 Lead 5 Lag 5 The guns...

Page 105: ...ts BEFORE the trailing edge of the part reaches the guns Conveyor Direction Lead 5 Gun On Lag 5 Gun Off Figure 5 14 Restricted Spray Extended Restricted Spray Example Use extended restricted spray to...

Page 106: ...ally in but can be assigned to any zone CAUTION Do not change zone assignments while parts are moving through the booth Doing so could cause erratic operation Using Zones to Prevent Triggering To prev...

Page 107: ...Control Screen Copy All Preset Table Screen The Copy All function on the Preset Table screen copies the selected preset settings for Gun 1 to the same preset for all other guns For example if preset 1...

Page 108: ...one setting When selected the setting buttons turn green b Source range of guns c Source preset or range of presets d Destination range of guns e Destination preset or range of presets NOTE All selec...

Page 109: ...esets are recipes that contain the move settings for a specific part Up to 255 unique presets can be created on each user data card Positioner Preset settings are part specific If no preset settings h...

Page 110: ...ved to the position setting S A positive lead moves the guns BEFORE the leading edge of the part reaches the guns S A negative lead moves the guns AFTER the leading edge of the part reaches the guns L...

Page 111: ...pying Preset Settings The Copy button copies the selected preset settings from positioner 1 to the rest of the positioners To select a setting to copy touch the setting label When selected an X appear...

Page 112: ...ed Positioning Settings Minimum Lead 2 Lag 2 Gun to Part 2 Default Lead 5 Lag 5 Gun to Part 10 Preset 1 Lead 6 Lag 6 Position 10 Fixed Preset 2 Lead 4 Lag 4 Position 8 Fixed 1 See Figure 6 2 The posit...

Page 113: ...r inches from the leading edge of the part the guns are moved back to 10 inches from the part 3 Four inches from the change in part width the guns are moved back to maintain the gun to part distance 4...

Page 114: ...Figure 6 4 The positioner waits at the Retract position 2 Four inches from the leading edge of the part the guns are moved forward from the Retract position to 10 inches from the part 3 Four inches fr...

Page 115: ...d BEFORE the leading edge the guns are moved back to the default gun to part distance 10 in 3 The leading edge of the part moves by the guns At the preset lead 2 or 2 inches AFTER the leading edge the...

Page 116: ...Positioner Preset Settings 6 8 Part 1056418 07 E 2019 Nordson Corporation...

Page 117: ...igger settings for a specific part Up to 255 unique presets can be created on each user data card Reciprocator Preset settings are part specific The system will use the default reciprocator settings f...

Page 118: ...s which preset settings are available The mode is shown along with the reciprocator number Refer to Fixed Mode Settings or Variable Mode Settings on the following pages 4 If desired enable percent adj...

Page 119: ...gs are relative to the part edge Positive settings extend the spray by turning the guns on BEFORE the part edge and off AFTER the part edge Negative settings restrict the spray by turning the guns on...

Page 120: ...On Top Turn Around Bottom Turn Around Reciprocator Home 0 On Off On Off Off On Top Turn Around Bottom Turn Around Reciprocator Home 0 On Off On Off Fixed Mode Positive On Off Settings Extended Spray...

Page 121: ...ing the guns on AFTER the part edge and off BEFORE the part edge If no part is present then the configured turn around limits apply Top Overtravel Bottom Overtravel Speed No Sync Mode Only Top Turn Ar...

Page 122: ...settings are the distances from the edge that the Flow Rate and Atomizing air percent adjust settings are turned on and off The On Off Up Down settings can be positive or negative Positive settings tu...

Page 123: ...urge 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...

Page 124: ...or Powder flow Prodigy guns Select Charge electrostatics Atomizing air flow scfm or m3 hr Lead Pattern air flow scfm or m3 hr Prodigy guns only Lag Assist Air Compensation Prodigy guns only Preset Vo...

Page 125: ...ry system booth exhaust fan and conveyor Start moving parts through the booth Using the Console Keyswitch The 3 position keyswitch on the front panel provides the following functions S Ready Runs the...

Page 126: ...Percent adjust screen 4 Preset table screen 5 Purge control screen 6 Positioner preset screen 7 System configuration screen 8 Scroll right 9 Help screen 10 Conveyor speed 11 Conveyor on off indicator...

Page 127: ...ure 8 3 Global Control Screen Spray Gun Global Control Manual Spray Control If you use the Global Control screen to put all guns in manual mode you can then choose any preset and trigger the guns on a...

Page 128: ...ting NOTE Manually changing the part ID affects only the part entering the booth not the part currently being sprayed Batch Coating 1 Select Manual mode 2 Select a part ID number 3 Touch the Enter but...

Page 129: ...to the configured settings The purge timer controls the purge duration Manual In manual mode touch the Purge Trigger button to turn purging on All guns are purged at once Touch the button again to sh...

Page 130: ...urge Control Purging OFF Purge Control Purging ON Purge Counter Figure 8 7 Prodigy Purge Control Screen 2 Touch the OK button to proceed with the purge touch the Cancel button to stop the purge 3 When...

Page 131: ...e program card and saved if you shut down the system Percent Adjust Additive Effects The percent adjust functions are additive variables In other words if settings are made for Reciprocator Stroke Len...

Page 132: ...y 10 If the conveyor speed decreases below 9 8 ft min and keeps decreasing then flows are decreased linearly until at 8 ft min both flow settings have been decreased by 20 If the conveyor speed goes a...

Page 133: ...ile it is spraying Part 1 S The Output Status display shows the output of Gun 1 for preset 1 S The Preset Setting display shows the settings for preset 1 Part 2 moves in front of the guns S The Output...

Page 134: ...y All Copy Selected Figure 8 9 Gun Control Screen Turning Individual Guns On and Off To shut down one or more guns while the rest continue to spray touch the Gun buttons for the desired guns and chang...

Page 135: ...ide with parts moving through the booth Control Screen Indicators and Functions Current Position Position of gun tips in relation to conveyor centerline Gun to Centerline Distance of gun tips from cen...

Page 136: ...gun to part distance from the centerline or to the forward limit switch whichever it reaches first and waits for the leading edge of the part to arrive at the lead setting For example if the gun to ce...

Page 137: ...to lock the reciprocator in either Manual mode or Off mode When locked the reciprocator cannot be forced into Auto mode from the Global Control screen or by an external signal Lockout Indicator If no...

Page 138: ...ing on the part currently in front of the guns S If no preset settings exist for the current part then the default settings are used and the Default Settings button displays Touching the button expand...

Page 139: ...ws you to experiment with the results of different reciprocator settings NOTE The settings you enter on this screen do not change your reciprocator settings Use this screen for reference only Settings...

Page 140: ...ber Number of Guns Number of Laps Spray Pattern Width Conveyor Speed Overtravel Part Height Stroke Length Speed Cycles Minute Calculate Automatic Settings Results Lap Pattern Lap Pattern with Fan Widt...

Page 141: ...s on the reciprocator have the same pattern width and there is no overlap If guns are mounted so that their fan patterns overlap then enter the average fan pattern width total width of pattern created...

Page 142: ...Operation 8 20 Part 1056418 07 E 2019 Nordson Corporation...

Page 143: ...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...

Page 144: ...ellow If this occurs touch the button to open the Gun Control screen to find the fault code Refer to Alarms in this section for more information Global Status Screen Touching the Global Status button...

Page 145: ...1056418 07 E 2019 Nordson Corporation Bar Graph Legend Scroll Consoles Guns Gun Preset Global Hourmeter Global Status Atomizing Air Standard Guns Pattern Air Prodigy Guns Network Error Indicators Fig...

Page 146: ...maintenance reset the Maintenance Timer setting and the Total Hours On for 16 pumps and 16 guns at a time NOTE For Prodigy systems pumps also have a maintenance timer When the Hours On timer equals t...

Page 147: ...ed automatically with the Percent Adjust function NOTE Gun related faults are faults that occur in the gun s voltage multiplier cable gun control card or iFlow module If a gun related fault occurs the...

Page 148: ...8 6 for information on the part ID modes Part ID Mode Part ID Number Part Name Figure 9 5 Part ID Mode Indicator Part ID Number and Part Name Input Status Touch the Input Status button on the Main sc...

Page 149: ...e configured for USA ColorMax The Park Indicator turns yellow during a color change and appears on the Main screen Touching the Park Button will abort the color change operation during all cycles exce...

Page 150: ...oblem occurs that is related to the spray gun voltage multiplier cable gun control card or iFlow module the gun button will blink yellow and a red indicator and Fault Code will appear on the gun contr...

Page 151: ...Log fstatus log files list all faults resets and status messages for the current day Use the drop down menu to open previous fstatus logs for up to 5 days Other log files include errors dat which lis...

Page 152: ...peration 9 10 Part 1056418 07 E 2019 Nordson Corporation Alarm Log Dropdown Menu Delete Open Log Help Close Alarm Log Cancel Delete Confirm Delete From Alarm Screen Alarm Log Contents Figure 9 9 Alarm...

Page 153: ...onfiguration button on the System Configuration screen to open the Network Status screen Node Status Buttons Ethernet Network CAN Network Status Button Figure 9 10 Network Status Screen Ethernet Node...

Page 154: ...on Figure 9 11 Node Status Screen Node Status Codes Type Code Description 6 In Out Positioner 7 Booth 12 Part ID 13 Feed Center Layout Code Description 1 GM1_GM2 2 GM3_GM4 3 RC1_RC2 4 RC3_RC4 5 GM1_RC...

Page 155: ...emote closed connection 70 Library error 71 Port already bound 72 Listen failed 73 File descriptors exceeded 74 No permission 75 Port not available 129 Checksum error 130 Frame error 131 Reply error 1...

Page 156: ...is error when the fan is off and the iControl console is powered up It is also seen if the host fails to transmit a message but is generally accompanied by other CAN errors Transmit errors indicate a...

Page 157: ...f the record sheets on the following pages and use them to record your configuration and preset settings NOTE When you are finished configuring your system and setting up your presets you should immed...

Page 158: ...of vertical analog scanner Zone Lengths 1 2 3 4 5 6 7 8 Part ID Inputs Type of Flagging Straight Encoded Flag Filter Length Zero Offset FBB 0 LBB 0 Horizontal Analog Scanners Single Scanner Dual Scan...

Page 159: ...No Nozzle Purge Timer Nozzle Purge Line Gap Nozzle Purge No of Banks Refer to Gun Pickoff and Purge Bank Record for Purge Bank Assignments Soft Start Enabled Yes No Soft Start Ramp Timer Prodigy Gun P...

Page 160: ...s 10 4 Part 1056418 07 E 2019 Nordson Corporation Gun Pickoff and Purge Bank Record Date System Console A or B Gun Number Pickoff Purge Bank No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22...

Page 161: ...on Settings Date System Remote I O Network IP Mask 255 255 255 0 LAN Network Mode IP Mask Gateway Name Domain Node Configuration Device MAC TCP IP Machine Type 1 2 3 4 5 6 7 8 9 10 Machine Types GP Gu...

Page 162: ...gs GP 1 GP 2 GP 3 GP 4 Encoder Resolution Side of Booth L R T B Distance between Guns Gun to Centerline Park Clean Position Retract Position Hysteresis Pickoff Minimum Lead Minimum Lag Minimum Gun to...

Page 163: ...uns on Reciprocator Top Soft Limit Bottom Soft Limit Hysteresis Park Clean Position Master Slaves Circle Slaves 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 Mode Setting Select one Fixed Synchronized Variable Sync...

Page 164: ...oke in Air Flow Reciprocator 1 Reciprocator 2 Reciprocator 3 Reciprocator 4 0 7 9 Flow Rate Atomizing 8 15 9 Flow Rate Atomizing 16 23 9 Flow Rate Atomizing 24 31 9 Flow Rate Atomizing 32 39 9 Flow Ra...

Page 165: ...ordson Corporation Spray Gun Preset Settings System Date Preset No Preset Name Gun Flow Rate Air Powder Flow Atomizing Air Pattern Air kV AFC Select Charge Mode Lead Lag Zone 1 2 3 4 5 6 7 8 9 10 11 1...

Page 166: ...itioner Lead Lag Fixed Variable Variable Position Fixed Position 1 2 3 4 Positioner Preset Settings System Date Preset No Preset Name Positioner Lead Lag Fixed Variable Variable Position Fixed Positio...

Page 167: ...tem Date Preset No Preset Name Fixed Settings Recip 1 Recip 2 Recip 3 Recip 4 Guns Off Up Guns On Down Guns Off Down Guns On Up Top Turn Around Bottom Turn Around Speed Variable Settings Speed Top Ove...

Page 168: ...Configuration and Preset Records 10 12 Part 1056418 07 E 2019 Nordson Corporation...

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Nordson Encore iControl 2, Configuration, Preset Setup, Operation

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