Nordson Encore iControl 2 Installation, Troubleshooting, Repair
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Nordson Encore iControl 2 Installation, Troubleshooting, Repair

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Encore
iControl
2
Integrated Control System
Installation, Troubleshooting, Repair
Customer Product Manual
Part 1603638-07
Issued 05/16
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.
NORDSON CORPORATION • AMHERST, OHIO • USA

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Summary of Contents for Nordson Encore iControl 2

  • Page 1 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. NORDSON CORPORATION • AMHERST, OHIO • USA...
  • Page 2 Contact Us Notice This is a Nordson Corporation publication which is protected by copyright. Nordson Corporation welcomes requests for information, comments, and Original copyright date 2013. No part of this document may be inquiries about its products. General information about Nordson can be...
  • Page 3 08/14 Updated part number 1603070 to 1605755. 09/14 Re-zero procedure revised 04/15 Removed part numbers from parts list. 11/15 Monitor design improvement 05/16 Added clarification to Console Power Cable Connections table. Updated wiring diagrams. Part 1603638-07 E 2016 Nordson Corporation...
  • Page 4 Change Record Part 1603638-07 E 2016 Nordson Corporation...

  • Page 5: Table Of Contents

    ........2-11 Approved Program and User Data Cards ....2-12 Part 1603638-07 E 2016 Nordson Corporation...
  • Page 6 ........3-19 Optional Air Conditioner Installation and Operation ... 3-20 Part 1603638-07 E 2016 Nordson Corporation...
  • Page 7 ......6-12 Wiring Diagrams and Schematics ......Part 1603638-07 E 2016 Nordson Corporation...
  • Page 8 Table of Contents Part 1603638-07 E 2016 Nordson Corporation...

  • Page 9: Safety

    Regulations and Approvals Make sure all equipment is rated and approved for the environment in which it is used. Any approvals obtained for Nordson equipment will be voided if instructions for installation, operation, and service are not followed. All phases of equipment installation must comply with all federal, state, and local codes.

  • Page 10: Personal Safety

    Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation. Use only replacement parts that are designed for use with original equipment. Contact your Nordson representative for parts information and advice. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 11: Grounding

    Disconnect and lock out electrical power. Close pneumatic shutoff valves and relieve pressures. Identify the reason for the malfunction and correct it before restarting the equipment. Disposal Dispose of equipment and materials used in operation and servicing according to local codes. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 12: Safety Labels

    See Figure 1-1 for the location of the safety labels. Item Part Description WARNING: Disconnect power before servicing. 1034161 Figure 1-1 Safety Labels Part 1603638-07 E 2016 Nordson Corporation...

  • Page 13: System Overview

    Hardware Manual: Covers installation, troubleshooting, repair, parts and drawings for this system only. The Encore iControl 2 systems can consist of a main console (16 guns), a main console and auxiliary console (32 guns), a pedestal/main console (16 guns) or a pedestal/main and auxiliary consoles (32 guns).

  • Page 14: Console And System Hardware And Software

    For both, travel and motion is dependent on the recipe settings for the part. Both positioners and reciprocators require analog scanner signals for accurate part width and height measurement. Part 1603638-07 E 2016 Nordson Corporation...
  • Page 15 1. iFlow digital airflow modules 5. I/O board 8. Relay board 2. Regulators 6. Dual gun cards, card cage, and 9. 24Vdc power supply backplane 3. PC 7. Power supply − multiple output 4. Touch screen display Part 1603638-07 E 2016 Nordson Corporation...

  • Page 16: Operator Interface

    The 120 watt power supply provides 24Vdc power to the PC and relay board. The relay board converts 24Vdc to 12Vdc for the display. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 17: Dual Gun Cards

    4. Flow air orifice 7. Flow air proportional valve 2. Air input fittings 5. Flow sensor (part of circuit board) 8. Atomizing air proportional valve 3. Atomizing air orifice 6. Solenoid valves (gun air) Part 1603638-07 E 2016 Nordson Corporation...

  • Page 18: Internal And External Networks

    This may require a trade off between desired conveyor speed and part tracking resolution (the higher the conveyor speed the coarser the tracking resolution). NOTE: A internal clock or an external timer may be used instead of an encoder. Consult with your Nordson representative. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 19: Specifications

    Moist or contaminated air can cause the iFlow modules to malfunction; the powder to cake in the feed hopper or clog the pump venturi throats, feed hoses, and spray gun powder paths; and cause grounding or arcing inside the spray gun. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 20: Special Conditions For Safe Use

    Special Conditions for Safe Use The Encore Automatic Powder Spray Applicators shall only be used with the associated Encore iControl 2 integrated controllers over the ambient temperature range of + 15 _C to + 40 _C. Only the iControl 2 Pedestal is certified for hazardous locations or zones.
  • Page 21 T = +15_ to +40_ C Vn1=12VDC Vn2=24VDC Pn1=12VA Pn2=64VA max. WARNING-POTENTIAL ELECTROSTATIC CHARGING HAZARD, SEE INSTRUCTION MANUAL NORDSON CORP. AMHERST, OH. USA Figure 2-7 Label for CE Approval (On Pedestal Cabinet) iControl 2 AUTOMATIC POWDER SPRAY SYSTEM FOR ELECTROSTATIC...

  • Page 22: Pedestal Dimensions

    2-10 System Overview Pedestal Dimensions 386 mm 460 mm (18.1 in.) (15.2 in.) 1385 mm (54.5 in.) 457.2 mm (18 in.) square base Figure 2-9 Pedestal Dimensions Part 1603638-07 E 2016 Nordson Corporation...

  • Page 23: Console Dimensions

    2-11 System Overview Console Dimensions 611 mm 609.6 mm (24.06in.) (24 in.) 1634 mm (64.3 in.) 581.5 mm (22.8 in.) Figure 2-10 Console Dimensions Part 1603638-07 E 2016 Nordson Corporation...

  • Page 24: Approved Program And User Data Cards

    SwissBit − industrial 2 Gb Transcend − industrial 512 Mb Toshiba − retail to 2 Gb Incompatible Cards: LEXAR − any Type II Compact Flash − any (cards will not fit in card slot) Part 1603638-07 E 2016 Nordson Corporation...

  • Page 25: Installation

    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 and operate the system.

  • Page 26: System Connections

    Sensors Main Console with Pedestal ETHERNET Pedestal CAN 1/Lockout AC IN ETHERNET To CB1 AUX connector on Auxiliary Console AC Power AC Power OPTIONAL To Powder Feed Center Figure 3-1 System Interconnect Cable Connections Part 1603638-07 E 2016 Nordson Corporation...

  • Page 27: Interconnect Cables

    CAN network and lockout signals between pedestal and console. AC power from the system electrical panel. CAN network to guns 17−32 in auxiliary console Optional connection for remote signals for the following functions: Manual enable Remote lockout Alarm relay Part 1603638-07 E 2016 Nordson Corporation...

  • Page 28: Can Network Address And Termination Settings

    (top in) (on) Open = Continuous Closed Open Open Open Open (bottom in) ±5V/12V Lockout 24VDC iControl 2 Backplane Alarm CAN IN CAN AUX CAN OUT Figure 3-2 CAN Network Connections, Console Addresses, and Termination Part 1603638-07 E 2016 Nordson Corporation...

  • Page 29: Iflow Module Switch Settings

    Console (Gun A) (Gun B) Down Down Continuous 1 (main) Trigger Down 2 (auxiliary) Set to Flow Module Gun Air Console Number (1−8) Flow Address Module Arrangement (Inside Door) Figure 3-3 iFlow Module Address Part 1603638-07 E 2016 Nordson Corporation...

  • Page 30: Power Connections

    Blue Interlocked AC common Green Ground Auxiliary Console Power Cable Connections Wire Color Connection Black Interlocked AC (same as main console Red connection) White Interlocked AC common (same as main console Blue connection) Green Part 1603638-07 E 2016 Nordson Corporation...

  • Page 31: Grounding

    Electrostatic discharges occur at very high frequencies, around 100 megahertz. An ordinary ground conductor does not conduct such high frequencies well enough to prevent damage to electronic components. Special flat braided cables are provided with your Nordson powder coating equipment to protect against ESD. Part 1603638-07...

  • Page 32: Gun Current Path

    (gun driver board and power supply). Gun Current Path Ions iControl 2 Ground Braid Figure 3-4 Electrostatic Current Path Part 1603638-07 E 2016 Nordson Corporation...

  • Page 33: Esd Ground Procedures And Equipment

    ESD Grounding Procedures and Equipment Always use the special flat braided copper ESD ground cables furnished with all Nordson spray gun controllers to ground them. The ESD ground cables should always be attached to the booth base, not to a panel, enclosure, or other component bolted to the base.

  • Page 34: Part Id Cable Connections

    17, 18, and 19. Note that the factory default configuration for these inputs is sinking. If a sourcing configuration is required refer to Switching Inputs to Sourcing on the following page. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 35: Switching I/O Inputs To Sourcing

    Section 7. Photoeye Connections Connect SO cable to the photoeyes and junction box terminal block as shown on the drawing. Route the cables into the junction box through dust-tight cord grips. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 36: Scanner Cable Connections

    SCNR1 PEJB PEJB SCNR2 SCNR1 Single Zone Scanner Dual Zone Scanners Part ID Scanner Zone Scanner Part Travel PEJB Part ID and Zone Scanners Figure 3-6 Zone and Part ID Scanner Cable Connections (Typical) Part 1603638-07 E 2016 Nordson Corporation...

  • Page 37: Analog Scanner Connections

    Junction Box to connect a customer-supplied part ID system to the iControl 2 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. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 38: Ethernet Network Connections

    Main Electrical Control Panel. The Ethernet cables are M12 D−coded 4 pole cables with connectors on each end. NOTE: Do not connect any device to this network that is not approved by Nordson Technical Support or Engineering. iControl 2 System with Main Console System Electrical...

  • Page 39: Gun Cable Connections

    Refer to the Parts section for seal and jumper part numbers. Receptacle #8 Bulkhead Harnesses Seal Jumper Install in #8 Card Receptacle Gun Card Figure 3-9 Seal and Jumper Installation − Example Showing 8 Gun System Using 7 Guns Part 1603638-07 E 2016 Nordson Corporation...

  • Page 40: Pneumatic Connections

    Connect 4-mm clear air tubing from the gun air (electrode wash) connectors on the console rear door to the spray guns. Verify all the tubing is correctly connected, so that gun 1 is connected to the gun 1 fitting and so on. Part 1603638-07 E 2016 Nordson Corporation...
  • Page 41 (4 mm clear) Gun/Pump Pneumatic Connections Cable Connections 3/4 NPT Air Input to Filter Part ID Cable Ethernet Console Ground Auxiliary Cable Optional Cable AC IN Cable Figure 3-10 Console Rear Panel (Cover Removed) Part 1603638-07 E 2016 Nordson Corporation...

  • Page 42: Program And User Data Cards

    ETH1 ETH0 (Ethernet) Serial (Touch Screen) (Ethernet) 24Vdc Power SLOT1 − Program I/O Ribbon Cable Connection SLOT2 − Data VGA (Touch Screen) CAN Network Figure 3-11 iControl 2 Program and User Data Card Slots Part 1603638-07 E 2016 Nordson Corporation...

  • Page 43: Touch Screen Calibration

    Certain upgrades require updates to the gun control card and iFlow module firmware. These upgrades should only be done by a Nordson representative. Part 1603638-07...

  • Page 44: Optional Air Conditioner Installation And Operation

    2 400W power supply as shown. This prevents the A/C unit from running unless the iControl 2 console is turned on. Filter: To clean the AC unit intake filter, remove the screw from the grille and slide the grille up. Part 1603638-07 E 2016 Nordson Corporation...
  • Page 45 SUPPLIED WITH A/C UNIT COVER (2) SHOWN FROM BELOW GASKET GROUND STUDS AND FASTENERS DRAIN KIT: TUBING, ELBOWS, CLAMPS SUPPLIED WITH A/C UNIT COUPLING TUBING TO FLOOR DRAIN (CUSTOMER SUPPLIED) Figure 3-12 Optional Air Conditioner Mechanical Installation Part 1603638-07 E 2016 Nordson Corporation...
  • Page 46 3-22 Installation AIR CONDITIONING UNIT A/CUNIT POWER CORD BROWN CUSTOMER POWER BLUE CONDUIT/WIRE GREEN/YELLOW 200/250 VAC 50/60Hz WIRING HARNESS (INCLUDED WITH KIT) 400W iCONTROL POWER SUPPLY Figure 3-13 Optional Air Conditioner Electrical Wiring Diagram Part 1603638-07 E 2016 Nordson Corporation...

  • Page 47: Troubleshooting

    Configuration section of the iControl Operator Interface manual for the shutdown procedure. NOTE: If the troubleshooting procedures in this section do not solve your problem, contact the Nordson Industrial Coating Systems Customer Support Center at (800) 433−9319 or your local Nordson representative. Error Codes and Alarm Messages...
  • Page 48 Atomize air flow low Air flow less than commanded value. 4-13 Flow air flow hi Air flow more than commanded value. 4-14 Atomize air flow hi Air flow more than commanded value. 4-14 Continued... Part 1603638-07 E 2016 Nordson Corporation...
  • Page 49 Preset out of range The preset sent to the iFlow module was out 4-14 of range. Trigger ON message iFlow module was commanded to trigger while 4-14 received − controller in in lockout. lockout Continued... Part 1603638-07 E 2016 Nordson Corporation...
  • Page 50 Illegal Data Address An illegal address was detected. 4-15 exception response Illegal Data Value exception An illegal data value was detected. 4-15 response Slave Device Failure The slave device returned an exception. 4-15 exception response Continued... Part 1603638-07 E 2016 Nordson Corporation...
  • Page 51 A vertical scanner is required for variable 4-26 configured − recip mode 1 stroke operation. invalid 2107 Speed calculated less than The speed of the reciprocator is less than the 4-27 minimum minimum value allowed. Continued... Part 1603638-07 E 2016 Nordson Corporation...
  • Page 52 Clean cycle aborted by user Clean cycle aborted by user − part release 4-19 action − park release was detected. detected 4111 Clean cycle aborted detected A machine malfunction aborted the cleaning 4-19 machine lockout/watchdog operation. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 53: Can Network Errors

    CAN errors can also be caused by individual gun cards or the iControl 2 PC to CAN card interface. These errors do not indicate a specific device failure as all devices are in parallel on the CAN bus. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 54: Gun Card Troubleshooting

    If the fault changes to E7, check the resistance of the multiplier as described in the gun manual. If the fault code stays E8, check the continuity of the cable as described in the gun manual. Continued... Part 1603638-07 E 2016 Nordson Corporation...
  • Page 55 − The card was commanded to trigger but the system is locked message received out. Trigger ON commands will be ignored until the system is − controller in returned to the Run state. lockout Part 1603638-07 E 2016 Nordson Corporation...

  • Page 56: Gun Card Leds

    If the card has no power, make sure it is is applied to the board). properly seated in the backplane and the locking tab is working correctly. Replace the card if the other gun control cards have power. Part 1603638-07 E 2016 Nordson Corporation...
  • Page 57 3. Status LED (green) 5. Gun Limit A LED (yellow) processor) 4. Gun Limit B LED (yellow) 6. Power LED (green) 2. Fault LED (red) 7. SW1 (2 position DIP switch for future use) Part 1603638-07 E 2016 Nordson Corporation...

  • Page 58: Iflow Module Troubleshooting

    6. Press pushbutton switch SW1 again. The red LED should shut off. 7. Remove the tube plugs from the output ports. 8. Check the Gun Control panel. With the spray gun off, the display should show no air flow. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 59: Iflow Module Error Codes And Fault Codes

    If more than one module reports the same fault, check the console air supply pressure. The pressure must be above 85 psi. Check the tubing supplying air to the iFlow module for blockage. Continued... Part 1603638-07 E 2016 Nordson Corporation...
  • Page 60 Trigger ON message − The card was commanded to trigger but the system is received − controller in locked out. Trigger ON commands will be ignored until lockout the system is returned to the Run state. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 61: Ethernet Network Troubleshooting

    Code I/O error Check Ethernet wiring. Remote node could be disconnected from network or turned off. Port or socket open Programming error. Contact Nordson technical support. error Serial port already open Programming error. Contact Nordson technical support. TCP/IP connection error Check Ethernet wiring.
  • Page 62 Check the PLC mode selection switch. The switch should be in the run (up) position. Replace the PLC. The replacement must be pre-programmed or a program must be downloaded and installed in the field. Contact Nordson Industrial Coating Systems Customer Support for details. − Operation was Normal operation.

  • Page 63: In/Out Positioner Troubleshooting

    If the gear reducer is not rotating but the motor is, replace the reducer. If the drive motor is not rotating, check the motor circuit protection, motor wiring, motor controller, and motor control circuits. This fault must be reset from the iControl 2 alarm screen. Continued... Part 1603638-07 E 2016 Nordson Corporation...
  • Page 64 Check all encoder mechanical and electrical connections. Make sure the encoder is powered. Check pulse output from the encoder. Replace encoder if necessary. This fault must be reset from the iControl 2 alarm screen. Continued... Part 1603638-07 E 2016 Nordson Corporation...
  • Page 65 Communication with in/out positioner or reciprocator controller lost detected machine during color change cycle. lockout/watchdog fault Check the iControl 2 alarm log for Watchdog or TCP/IP faults. (Euro color change Refer to Ethernet Network Troubleshooting on page 4-15. only) Part 1603638-07 E 2016 Nordson Corporation...

  • Page 66: Other In/Out Positioner Troubleshooting

    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 ColorMax system: Apply jumper to force On the remote disable input. Refer to system drawings for jumper application.
  • Page 67 Ethernet network connections to the controller node, then replace the analog input module. In/Out Positioner preset set Normal operating scenario. Position change to Fixed. will only occur when a new part appears at the in/out positioner. Continued... Part 1603638-07 E 2016 Nordson Corporation...
  • Page 68 (home) and acquires a reverse reference value. This value is used to reset the in/out positioner position for Auto operations. Continued... Part 1603638-07 E 2016 Nordson Corporation...
  • Page 69 In/Out Positioner actual Incorrect encoder resolution NOTE: Encoder resolution can only be travel distance does not entered on in/out positioner entered or changed by a Nordson match value shown on configuration screen. representative. iControl 2 screens Verify encoder resolution (number of pulses...

  • Page 70: Reciprocator Troubleshooting

    If the gear reducer is not rotating but the motor is, replace the reducer. If the drive motor is not rotating, check the motor circuit protection, motor wiring, motor controller, and motor control circuits. This fault must be reset from the iControl 2 alarm screen. Continued... Part 1603638-07 E 2016 Nordson Corporation...
  • Page 71 Check all encoder mechanical and electrical connections. Make sure the encoder is powered. Check pulse output from the encoder. Replace encoder if necessary. This fault must be reset from the iControl 2 alarm screen. Continued... Part 1603638-07 E 2016 Nordson Corporation...
  • Page 72 Check the configured soft top and bottom limits. Make sure they do not allow travel to the limit sensors. Adjust the configured reciprocator Turn-Around Offset (Nordson only) to ensure that the limit sensors are not engaged. Check reciprocator encoder wiring. If signals switched position tracking will be reversed.

  • Page 73: Other Reciprocator Troubleshooting

    Lockout is applied from the Configuration screens. iControl 2 lockout applied to This is a normal condition unless a failure has guns, in/out positioners, and occurred. Refer to Photoeye, Encoder, and reciprocators. Interlock Troubleshooting in this section. Continued... Part 1603638-07 E 2016 Nordson Corporation...
  • Page 74 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 ColorMax system: Apply jumper to force On the remote disable input. Refer to system drawings for jumper application.
  • Page 75 If the value is not large enough, the reciprocator will over- or under-shoot its destination and then “jump” back to it (called hunting). A typical setting is 0.5 − 0.7 inches depending on the reciprocator speed setting. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 76: Other Fault Messages And Conditions

    Check the ribbon cable connections to the Compact Flash adapter and PC. Replace the ribbon cable if necessary. (Standard 40-pin IDE cable, not available from Nordson.) Condition: Pickoff value is reset to The maximum pickoff length is 4096 inches (104038.4 mm). With...

  • Page 77: Photoeye, Encoder, And Interlock Troubleshooting

    LEDs 1−20 are responding erratically, then check the I/O board inputs common voltage. For sinking inputs, +24 Vdc is applied to all HI terminals on the board as inputs common. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 78: Touch Screen Troubleshooting

    On power up, you will not be able to touch the CAL button to start the calibration procedure. If this happens, perform the Calibration with a Mouse procedure. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 79: Calibration With A Mouse

    Console fuses on the DIN rail, at the incoming power terminals. Unswitched power connections to the fuse blocks. Power supply to the console. 12Vdc supply to the touch screen 24 Vdc supply to the PC Part 1603638-07 E 2016 Nordson Corporation...

  • Page 80: Touch Screen Failure

    2 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. Replace the iControl 2 PC as soon as possible. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 81: Repair

    Failure to maintain the dust-tight integrity of the enclosures could invalidate agency approvals and create a hazardous condition. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 82: Flow Module Repair

    9. Install the coil over the valve stem, with the coil wiring pointing toward the circuit board. Secure the coil with the nut. 10. Connect the coil wiring to the circuit board. Part 1603638-07 E 2016 Nordson Corporation...
  • Page 83 2. Nut−coil to proportional valve (4) 6. Proportional valve (4) 11. Cartridge 3. Coil−proportional valve (4) 7. Direction of flow arrow 12. Valve body 4. Long screws−valve to manifold (2) 8. Gun air solenoid valve (2) 13. Orifice Part 1603638-07 E 2016 Nordson Corporation...

  • Page 84: Proportional Valve Replacement

    (6). Push the locking tab up to lock the card into the card cage. Connect the gun harness to the two receptacles on the card. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 85: Adding Guns

    11 13 15 Gun Order in Card Cage Figure 5-2 Gun Control Card Replacement 1. Card cage (slot 1) 3. Gun 2 connector 5. Locking tab 2. Gun control card 4. Gun 1 connector 6. Backplane Part 1603638-07 E 2016 Nordson Corporation...

  • Page 86: Ribbon Cable Connections

    Pin 1 Mark (Arrow) PC End iControl 2 PC Ribbon Cable Red or Blue Trace Pin 1 Cable I/O Board Key Notch I/O Board End Pin 1 Mark (Arrow) Figure 5-3 PC−I/O Board Ribbon Cable Connections Part 1603638-07 E 2016 Nordson Corporation...

  • Page 87: Touch Screen Replacement

    4. Install the replacement touch screen (1) onto the mounting clamp (2) and tighten all mounting nuts (3) to 2.5 NSm (22 in-lbs). Pedestal Installation Console Installation 1. Touch screen 2. Mounting clamp 3. Mounting nut Figure 5-4 Touch Screen Replacement Part 1603638-07 E 2016 Nordson Corporation...
  • Page 88 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, recalibrate the screen using the Touch Screen Calibration instructions in the Encore iControl 2 Integrated Control System manual. +12V...

  • Page 89: Parts

    Parts Section 6 Parts Introduction To order parts, call the Nordson Industrial Coating Systems Customer Support Center at (800) 433 contact or your local Nordson representative. iControl 2 Controllers and Interconnect Cables Part Description Note Main Consoles 1603116 Controller, Encore, iControl 2, 4 gun, main console...

  • Page 90: Main/Auxiliary Console Parts

    Muffler, 1/8 in. NPT 1602855 Filter assembly, gas and compressed air, iControl2 1047524 S Element, filter 326139 Plug, blanking, 4 mm tube 973143 Elbow, pipe, 90 degree, 3/4 in., steel, zinc plt AR: As Required Continued... Part 1603638-07 E 2016 Nordson Corporation...
  • Page 91 Parts 7, 7A Figure 6-1 Main and Auxiliary Console Parts − Rear View(1 of 3) Part 1603638-07 E 2016 Nordson Corporation...
  • Page 92 E: Both the long and short power cable harnesses are provided in the touch screen installation kit. Use the long power cable harness for console installations. AR: As Required Continued... Part 1603638-07 E 2016 Nordson Corporation...
  • Page 93 Parts Figure 6-2 Main and Auxiliary Console Parts − Internal Components (2 of 3) Part 1603638-07 E 2016 Nordson Corporation...
  • Page 94 Filter, line, RFI, power, 10A 900740 TUBING, polyurethane, 10/6.5−7 mm 226690 TUBING, polyurethane, 12/8mm, blue 240976 CLAMP, ground, with wire NOTE A: Not used in auxiliary console. B: One line filter used in auxiliary console. AR: As Required Part 1603638-07 E 2016 Nordson Corporation...
  • Page 95 Parts Figure 6-3 Main and Auxiliary Console Parts − Internal Components (3 of 3) Part 1603638-07 E 2016 Nordson Corporation...

  • Page 96: Pedestal Parts

    Memory, programmed, iControl 1034281 Memory, compact flash (blank, for user data) NOTE A: Both the long and short power cable harnesses are provided in the kit. Use the short power cable harness for pedestal installations. Part 1603638-07 E 2016 Nordson Corporation...
  • Page 97 Parts Figure 6-4 Pedestal Parts Part 1603638-07 E 2016 Nordson Corporation...

  • Page 98: Iflow Module Parts

    NOTE A: The iFlow module can use one of two circuit board part numbers: If using board 1023932, order solenoid valve 1099302. If using board 1099635, order solenoid valve 1099288. Figure 6-5 Flow Module Parts Part 1603638-07 E 2016 Nordson Corporation...

  • Page 99: Options

    Sensor, light emitter, 72 in., 3/4 in. beam spacing, 96 beam 339752 Sensor, light receiver, 72 in., 3/4 in. beam spacing, 96 beam NOTE A: Requires custom programming to match the application. Contact Nordson customer support. Part 1603638-07 E 2016 Nordson Corporation...

  • Page 100: Photocell And Scanner Cables

    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. 347230 Cable, input, 5 wire, 6 meter, male Part 1603638-07 E 2016 Nordson Corporation...

  • Page 101: Wiring Diagrams And Schematics

    Section 7 Wiring Diagrams and Schematics Refer to the following foldout wiring diagrams and schematics for the main and auxiliary consoles. NOTE: Visit Nordson eManuals for a high resolution view of the wiring http://emanuals.nordson.com diagrams and schematics. Go to and click on the Encore iControl 2 Integrated Control System manual.
  • Page 102 Wiring Diagrams and Schematics Part 1603638-07 E 2016 Nordson Corporation...
  • Page 110 DECLARATION of CONFORMITY Product: Encore Automatic Powder Spray System Models: Encore Automatic Applicator and Encore iControl 2 Description: The automatic electrostatic powder spray system includes applicator, control cable and associated controllers. These controls are available in a 4 - 16 applicator control cabinets as a main console with a pc and display or an auxiliary console without the pc or display.
  • Page 111 10011935 NOTICE 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. AIR CONDITIONING UNIT ENCORE iCONTROL 2 THE FOLLOWING CONTROLLERS ARE SUITABLE...
  • Page 112 REVISION 10011935 NOTICE 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. AIR CONDITIONING UNIT ENCORE iCONTROL 2 1603093 KIT, AIR CONDITIONING UNIT...

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