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 2003. No part of this document may be inquiries about its products. General information about Nordson can be...
Page 3: Table Of Contents
..........iControl System Manuals .
Page 4 ......3-15 iControl Console to Network Interface Box ....
Page 5 ........iControl PC Replacement .
Page 6 ........6-14 Recommended Air Filter for Use with iControl Systems ..
Page 7 Change Record Change Record Revision Date Change 09/2014 Re-zero procedure revised Part 1105779-04 E 2014 Nordson Corporation...
Page 8 Change Record Part 1105779-04 E 2014 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 1105779-04 E 2014 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 1105779-04 E 2014 Nordson Corporation...
Page 12: Safety Labels
Safety Safety Labels Table 1-1 contains the text of the safety labels on the iControl console. The safety labels are provided to help you operate and maintain your console safely. See Figure 1-1 for the location of the safety labels.
Page 13: Overview
Overview Section 2 Overview iControl System Manuals This manual covers the iControl console and system hardware for Standard iControl systems used with Sure Coatr, Versa-Sprayr, and Tribomaticr spray guns only. iControl manuals are organized as follows: Operator Interface Manual covers configuration, preset setup, and...
Page 14: Console And System Hardware And Software
2nd Booth Option The 2nd booth shares the signals from the conveyor encoder, zone and part ID scanners or photoeyes, and positioner and reciprocator scanners. Ethernet switch installed in scanner junction box Part 1105779-04 E 2014 Nordson Corporation...
Page 15 Overview Figure 2-2 iControl Master Console Internal Components (Shown with Door Opened 90_) 1. iFlow digital airflow modules 5. I/O board 8. Relays and terminal block 2. Regulators 6. Card cage, backplane, gun control 9. Air manifold cards 3. CompactFlash cards 10.
Page 16: Operator Interface
Overview Operator Interface The iControl software provides a graphical user interface that provides screens to configure and control the spray gun triggering and positioning system. The operator performs all configuration and operation tasks with the touch screen and the Rotary Dial. Turning the rotary dial increases or decreases values in selected fields.
Page 17: Can And Ethernet Networks
Refer to the system diagrams in Section 7. CAN Network: Handles communications between the gun control cards, iFlow modules, and the iControl PC, and with other iControl consoles. Ethernet Network: Handles communications between the iControl system and remote devices such as optional in/out positioners, reciprocators, and scanners.
Page 18: Gun Control Cards
Digital Flow Modules The iControl system controls air flow to the spray gun powder pumps, providing a more consistent and steady flow of powder to the spray guns than systems that control air pressure. The flow controls consist of the precision regulators and iFlow digital flow modules mounted in the iControl enclosure.
Page 19: Specifications
Alarm Relay contact rating: 120/230 Vac, 1 , 6 A Output (to spray gun) 0−21 Vdc, 0.60 A NOTE: The iControl system must be interlocked with the fire detection system so that the spray guns are shut off if a fire is detected inside the spray booth. ANSI/ISA S82.02.01...
Page 20: Air Quality
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 equipment is intended to be used in the ambient temperature from 0_C to 40_C.
Page 21: Approved Program And User Data Cards
NOTE: With the industrial Sandisk, the system will not boot completely or in a timely manner when either the data or program flash differs in size. Incompatible devices with iControl: LEXAR − any Type II − any (Type II CompactFlash are larger and will not fit into the device holder.
Page 22 2-10 Overview Part 1105779-04 E 2014 Nordson Corporation...
Page 23: Installation
Refer to the iControl Operator Interface manual for configuration instructions. WARNING: Use dust-tight conduit connectors or strain reliefs in all iControl console, junction box, and control panel knockouts. Installation must be done according to code and care must be taken to maintain the dust-tight integrity of the enclosures.
Page 24: Console Can Network Address And Termination Settings
Master and slave console: Set the master console to CONTINUOUS (SW1−3 open) and the slave console to END (SW1−3 closed). Network address dipswitch: Set the master console to 1 (SW1−1 closed, SW1−2 closed). Set the slave console to 2 (SW1−1 closed, SW1−2 open). Part 1105779-04 E 2014 Nordson Corporation...
Page 25: Iflow Module Dipswitch Settings
Figure 3-2. Module Number (SW3): Set the rotary dipswitch on each module to the correct module number. The modules are numbered as shown in the module arrangement chart in Figure 3-3. Part 1105779-04 E 2014 Nordson Corporation...
Page 26: Power, Ground, And Relay Connections
The console and junction box power cable ground wires must always be connected to a true earth ground. The special flat braided ESD ground cables provided with the iControl consoles and manual gun controllers must be used to connect them to the booth base if possible. Refer to Grounding on page 3-7 for more information.
Page 27: Icontrol Console Power Cable Connections
Installation iControl Console Power Cable Connections Table 3-2 Master and Slave Console Power Cable Connections Master Console Power Cable Connections (A) Wire Color Connection Function 100−240 Vac power to SBC (master console only) (unswitched) Black L1 (hot) White L2 (neutral) 120−240 Vac power to console power supply (master and slave consoles)
Page 28: Conveyor Interlock And Remote Lockout Relay Connections
240 volts. To switch to 120 volts refer to 3-4 for new style relays. Do not remove the 20K resistors. 240V Connections 120V Connections Conveyor Interlock Conveyor Interlock Remote Lockout Remote Lockout Alarm Alarm Figure 3-4 240Vac and 120Vac Conveyor Interlock and Remote Lockout Connections Part 1105779-04 E 2014 Nordson Corporation...
Page 29: 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 1105779-04...
Page 30: Gun Current Path
(gun driver board and power supply). Ground Braid Gun Current Path Ions iControl Booth Base Ground Braid Figure 3-5 Electrostatic Current Path Part 1105779-04 E 2014 Nordson Corporation...
Page 31: Esd Ground Procedures And Equipment
A 25-conductor cable carries the encoder and discrete part ID and zone input signals from the Photoeye Junction Box (PEJB) to the I/O board in the iControl console. If these inputs are shared by a second booth then an additional 25-conductor cable is supplied. Table 3-3 lists the 25-conductor cable connections to be made at the terminal strip.
Page 32: 25-Conductor Cable Connections
Interlock WHITE from 19 LO Not Applicable Conveyor Front Panel Interlock 8 HI NOTE: For information on how to use Trigger Banks, see Using Zone Inputs for Direct Triggering in the iControl Software Manual. Part 1105779-04 E 2014 Nordson Corporation...
Page 33: Switching Inputs To Sourcing
Installation Switching Inputs to Sourcing Inputs to I/O card in the iControl console are configured as sinking. 24 Vdc is applied to all HI terminals. To switch the inputs to sourcing: 1. Disconnect all wires from the I/O card LO terminals, except terminal 24.
Page 34: Scanner Cable Connections
SCNR2 cables to Part ID scanner. NOTE: The part ID scanner or photoeyes must be located so that the iControl system receives the part ID before the leading edge of the part breaks the zone scanners or photoeyes. Part 1105779-04...
Page 35: Analog Scanner Connections
If the system also has reciprocators, then analog scanners are used to detect the part height and top and bottom edges. Mount the scanners with the cable ends down and connect the cables (SCNR1) from the junction box to the scanners. Part 1105779-04 E 2014 Nordson Corporation...
Page 36: Customer-Supplied Part Id System Connections
Refer to Table 3-3 on page 3-10. Use the Part ID terminals on the Photoeye Junction Box 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.
Page 37: Ethernet Network Connections
3-15 Installation Ethernet Network Connections The Ethernet network allows the iControl system to communicate with remote Ethernet devices such as the in/out positioner or reciprocator controllers and the Ethernet couplers that receive signals from the analog scanner controllers. NOTE: Do not connect any device to this network that is not approved by Nordson Finishing Technical Support or Engineering.
Page 38: Icontrol Console To Network Interface Box
NOTE: There are two Ethernet cable types, T568-A and T568-B. The type determines the way the cable leads are wired at each end of the cable. Either type of cable can be used in the iControl system. Each end of the cable must be terminated using the same wiring arrangement.
Page 39: Connecting Termination Modules To Ethernet Cables
3-17 Installation Connecting Termination Modules to Ethernet Cables iControl junction boxes and control panels containing Ethernet devices are equipped with T568-B Ethernet termination modules and 2-foot T568-B patch cords. To connect the termination modules to the Ethernet cables coming from the network junction box, you will need a cable jacket stripper, a 110 punch-down tool, and a diagonal cutter.
Page 40 NOTE: The cables used with these modules must be type T568-B. 110 Punch Module Down Tool Module Bezel min. Cover Bezel Cover Cable Tie Bezel Adapter Adapter Figure 3-10 Connecting Ethernet Termination Modules to Ethernet Cable Part 1105779-04 E 2014 Nordson Corporation...
Page 41: Ethernet Termination Standards
Installation Ethernet Termination Standards Either T568-B or T568-A cables will work in the iControl system. Use the wiring diagrams in Figure 3-11 when terminating Ethernet cables. Make sure each end of the cable is terminated using the same type of plug and wiring arrangement.
Page 42: Gun Cable Connections
Gun Cable Connections See Figure 3-12. Connect the automatic gun cables to the receptacles on the bottom rear panel of the iControl console. Connect gun 1 cable to receptacle 1, gun 2 cable to receptacle 2, and so on. NOTE: If you are using Versa-Spray and Tribomatic guns, you must connect an adapter cable to each console receptacle, then connect the gun cables to the adapter cables.
Page 43: Pneumatic Connections
If your spray guns use gun air, connect 4-mm clear air tubing from the gun air connectors on the console rear door to the spray guns. Make sure you connect the tubing correctly, so that gun 1 is connected to the gun 1 fitting and so on. Part 1105779-04 E 2014 Nordson Corporation...
Page 44: Program And User Data Cards
Console Rear Panel (Cover Removed) Program and User Data Cards The iControl program and user configuration and preset data are stored on two 128 Mb CompactFlash cards. These cards function as removable hard drives. The iControl consoles are shipped with these cards installed.
Page 45: Touch Screen Calibration
1. Data card 2. Program card The iControl program can be updated by installing a new program card. In addition to the configuration data, up to 255 presets per gun can be stored on one data card. Additional cards will provide you with a virtually unlimited number of presets.
Page 46: System Upgrades
Versa-Spray guns installing a new program flash card with updated software. Certain upgrades require updates to the gun control card and iFlow module firmware. These upgrades should only be done by a Nordson representative. Adding Guns to Existing iControl Console Master and slave consoles are sold configured for 4, 6, 8, 10, 12, 14, or 16 guns.
Page 47: Requirements To Add One Gun
2. Shut down the powder coating system. Disconnect and lock out power to the system and the iControl consoles. 3. Install the new spray guns in the booth and powder pumps on the feed hoppers or feed center. Install powder feed hose between the pumps and the guns.
Page 48 Systems>Booth and Trigger Controls, or contact the Nordson Finishing Customer Support Center or your local Nordson representative for instructions. 17. Turn on the console and configure the iControl program to add the new guns to the system. Refer to Gun Configuration in the iControl Operator Interface manual.
Page 49: Adding A Slave Console To An Existing System
6. Connect the spray gun cables and the flow-rate, atomizing, and gun air tubing to the slave console as described on page 3-20. 7. Turn on the console and configure the iControl program to add the new guns to the system. Refer to Gun Configuration in the iControl Operator Interface manual.
Page 50 3-28 Installation Part 1105779-04 E 2014 Nordson Corporation...
Page 51: Troubleshooting
CAUTION: Do not turn off console power without first performing a program shutdown. Doing so could corrupt the iControl program and operating system on the program card. Refer to Program Shutdown in the Configuration section of the iControl Operator Interface manual for the shutdown procedure.
Page 52 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 1105779-04 E 2014 Nordson Corporation...
Page 53 Preset out of range The preset sent to the remote device was out 4-14 of range. Trigger ON message Remote device was commanded to trigger 4-14 received − controller in while in lockout. lockout Continued... Part 1105779-04 E 2014 Nordson Corporation...
Page 54 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 1105779-04 E 2014 Nordson Corporation...
Page 55 A vertical scanner is required for variable 4-27 configured − recip mode 1 stroke operation. invalid 2107 Speed calculated less than The speed of the reciprocator is less than the 4-28 minimum minimum value allowed. Continued... Part 1105779-04 E 2014 Nordson Corporation...
Page 56 Clean cycle aborted by user Clean cycle aborted by user − part release 4-20 action − park release was detected. detected 4111 Clean cycle aborted detected A machine malfunction aborted the cleaning 4-20 machine lockout/watchdog operation. Part 1105779-04 E 2014 Nordson Corporation...
Page 57: Can Network Errors
CAN errors can also be caused by individual gun cards or the iControl PC to PC104 card interface. These errors do not indicate a specific device failure as all devices are in parallel on the CAN bus.
Page 58: 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 1105779-04 E 2014 Nordson Corporation...
Page 59 − 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 1105779-04 E 2014 Nordson Corporation...
Page 60: 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 1105779-04 E 2014 Nordson Corporation...
Page 61 Gun Control Card LEDs and Switches 1. Reset switch (reboots the on-board 3. Status LED (green) 5. Foldback A LED (yellow) processor) 4. Foldback B LED (yellow) 6. Power LED (green) 2. Fault LED (red) Part 1105779-04 E 2014 Nordson Corporation...
Page 62: Iflow Module Troubleshooting
Re-Zero Procedure Perform this procedure if an iControl gun control screen indicates air flow when the spray gun is not triggered on, or if a Flow Air or Atomizing Air Flow High Fault (F6 or F7) appears on the Gun Control panel and the Fault screen.
Page 63: Iflow Module Error Codes And Fault Codes
Atomize airflow low Disconnect the air tubing from the iControl console. If the fault goes away, then the air tubing is too long or the tubing diameter is too large.
Page 64 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 1105779-04 E 2014 Nordson Corporation...
Page 65: Remote I/O (Ethernet) Network Troubleshooting
Refer to Testing Ethernet Cables in this section. Check the Ethernet card on the iControl PC for proper operation. The ACT LED indicates network traffic when lit. The LNK LED to the right of the RJ-45 connector indicates network status (green: 10 Mbs, amber: 100 Mbs, off: no connection).
Page 66 (up) position. Replace the remote node controller. The replacement must be pre-programmed or a program must be downloaded and installed in the field. Contact Nordson Finishing Customer Support for details. − Operation was Normal operation. No action required.
Page 67 4-17 Troubleshooting Error Message/Condition Correction Code − I/O error class Programming error. Contact Nordson technical support. Fieldbus protocol error Programming error. Contact Nordson technical support. class Part 1105779-04 E 2014 Nordson Corporation...
Page 68: In/Out Positioner Troubleshooting
Network Troubleshooting on page 4-15 if the fault messages indicate a communications problem (Watchdog fault or TCP/IP communications fault). Each fault message displayed on the iControl screen is accompanied by a device and number identifier. The identifier indicates the faulted machine (for example, IN/OUT Positioner #1, Reciprocator #2).
Page 69 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 Auxiliary contact on the motor reverse contactor did not close when Fault the in/out positioner was commanded to move in reverse.
Page 70 Communication with in/out positioner or reciprocator controller lost detected machine during color change cycle. lockout/watchdog fault Check the iControl alarm log for Watchdog or TCP/IP faults. Refer (Euro color change to Remote I/O Network Troubleshooting on page 4-15. only) Part 1105779-04...
Page 71: Other In/Out Positioner Troubleshooting
Table 4-8 Other In/Out Positioner Troubleshooting Problem Cause Correction No movement from A fault has occurred Check the iControl alarm log. in/out positioner in preventing operation. Identify the fault and review the fault response to move troubleshooting information in this table.
Page 72 This is a normal and temporary occurrence positioner when the iControl system does not know the status of the parts on the conveyor between the in/out positioner scanner and the in/out positioner. This condition occurs when the...
Page 73 If the in/out positioner is within this distance of the desired position when it stops, the iControl system will not move it again to the target position. If the value is not large enough, the in/out positioner will over- or under-shoot its destination and then “jump”...
Page 74 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 screens Verify encoder resolution (number of pulses...
Page 75: Reciprocator Troubleshooting
Troubleshooting on page 4-15 if the fault messages indicate a communications problem (Watchdog fault or TCP/IP communications fault). Each fault message displayed on the iControl screen is accompanied by a device and number identifier. The identifier indicates the faulted machine (for example, IN/OUT Positioner #1, Reciprocator #2).
Page 76 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 Reverse Contactor Fault Auxiliary contact on the motor reverse contactor did not close when the in/out positioner was commanded to move in reverse.
Page 77 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 CSR only) to ensure that the limit sensors are not engaged. Check reciprocator encoder wiring. If signals switched position tracking will be reversed.
Page 78: Other Reciprocator Troubleshooting
Table 4-10 Other Reciprocator Troubleshooting Problem Cause Correction No movement from A fault has occurred Check the iControl alarm log. reciprocator in preventing operation. Identify the fault and review the fault response to move troubleshooting information in this table. command...
Page 79 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 80 A 5 second delay occurs when Auto mode is selected. During the delay a warning beeper should sound. An end-of-travel limit switch Check the iControl Alarm log. Identify the is engaged. fault and review the fault troubleshooting information. Invalid reciprocator stroke Speed controller parameters must be set to settings.
Page 81: 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 82: 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 1105779-04 E 2014 Nordson Corporation...
Page 83: Remote Node (Fieldbus Controller/Coupler) Troubleshooting
TxD/RxD Green Data exchange taking place. No data exchange. Make sure the iControl console is powered on. Make sure the remote node has been configured by checking the Network Status screen and Node Configuration screen. Check the iControl Alarm screen for remove node fault messages.
Page 84: Node Status
No operating voltage. Check the supply voltage (24 V and 0 V) Green Operating voltage for power jumper contacts exists. No operating voltage for power Check the supply voltage (24 V and 0 V) jumper contacts. Part 1105779-04 E 2014 Nordson Corporation...
Page 85: I/O Errors
TCP/IP initialization error. Fault Code 7: I/O module not supported I/O module at position n is not supported. Fault Code 8: Not used Fault Code 9: CPU−TRAP error Illegal opcode. Stack overflow. Stack underflow. Part 1105779-04 E 2014 Nordson Corporation...
Page 86: Touch Screen Troubleshooting
Touch Screen Calibration The touch screen is calibrated at the factory. If you change a program card, or the iControl PC, or have problems touching screen components accurately, you will have to recalibrate the screen. The touch screen calibration values are stored on the program card. If you install a program card that has not been used before, there will be no calibration file on the card.
Page 87: No Touch Screen Display
Troubleshooting Use this procedure to recalibrate the touch screen if you cannot touch the CAL button or the buttons on the iControl screens, or if you install a program card previously used in another iControl console. NOTE: You must shut off console power before connecting or disconnecting a mouse or keyboard from the iControl PC.
Page 88: Touch Screen Failure
Temporary Fix: Shut off console power and connect a mouse with a PS2 connector to the MOUSE port of the left side of the iControl PC. Turn on console power and allow the system to boot up. You should now be able to use the mouse to point and click on screen buttons and data fields.
Page 89: Rotary Knob Troubleshooting
Connect a standard PC keyboard with a PS2 connector to the KEYBOARD port on the left side of the iControl PC. Turn on power and use the numeric keys to enter values in selected data fields, or use the up and down arrow keys to change field values.
Page 90: Testing Ethernet Cables
Check each connection. If you suspect a bad connection, you can pull the lead out of the module and punch it down again closer to the jacket. If the termination module connections are good, then the cable is faulty and must be replaced. Part 1105779-04 E 2014 Nordson Corporation...
Page 91: Repair
CAUTION: Do not turn off console power without first performing a program shutdown. Doing so could corrupt the iControl program and operating system on the program card. Refer to Program Shutdown in the Configuration section of the iControl Operator Interface manual for the shutdown procedure.
Page 92: Flow Module Repair
CAUTION: The module circuit cards are electrostatic sensitive devices (ESD). To prevent damage to the cards when handling them, wear a grounding wrist strap connected to the iControl enclosure or other ground. Handle the cards only by their edges. Proportional Valve Cleaning See Figure 5-1.
Page 93 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 1105779-04 E 2014 Nordson Corporation...
Page 94: Proportional Valve Replacement
CAUTION: The gun control cards are electrostatic sensitive devices (ESD). To prevent damage to the cards when handling them, wear a grounding wrist strap connected to the iControl enclosure or other ground. Handle the cards only by their top and bottom edges.
Page 95: 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 1105779-04 E 2014 Nordson Corporation...
Page 96: Icontrol Pc Replacement
The obsolete PC used eight M6 screws to mount to the panel. Once removed, these screws can be discarded. The new PC model has eight M6 studs that mount onto the iControl panel using eight M6 nuts. See Figure 5-3. The Compact Flash adapter along with the adapter cable and power supply cable are no longer needed.
Page 97: Ribbon Cable Connections
CAUTION: Plugging in a ribbon cable the wrong way may damage the cable or the circuit boards 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 cables are connected correctly.
Page 98 Repair Part 1105779-04 E 2014 Nordson Corporation...
Page 99: Parts
Parts Section 6 Parts Introduction To order parts, call the Nordson Industrial Coating Systems Customer Support Center or your local Nordson representative. Customer Support Center Telephone: (800) 433−9319 Facsimile: (888) 229−4580 Email: finishing_csc@nordson.com Part 1105779-04 E 2014 Nordson Corporation...
Page 100 Parts Part 1105779-04 E 2014 Nordson Corporation...
Page 101: Consoles
1104816 Controller, iControl, 16 gun, w/cpu, w/ac Slave Consoles 1104819 Controller, iControl, 4 gun, w/o cpu 1104821 Controller, iControl, 4 gun, w/o cpu, w/ac 1104823 Controller, iControl, 6 gun, w/o cpu 1104825 Controller, iControl, 6 gun, w/o cpu, w/ac 1104827...
Page 102: Console Parts
Parts Console Parts Figures 6-1 through 6-8 show the replaceable parts for both master and slave consoles. Contact your Nordson representative or Nordson Customer Support for help in obtaining unlisted parts. Refer to Section 7 for pneumatic and electrical diagrams.
Page 103 Parts Door Parts See Figure 6-3 Control Sub Panel See Figure 6 Even Gun Number Odd Gun Number Figure 6-1 Console Parts (1 of 5) Part 1105779-04 E 2014 Nordson Corporation...
Page 104 1100090 CONTROL UNIT, PC, panel mount, w/Ethernet 1051544 S INTERFACE CARD, PC104 CAN 1105343 S CARD, I/O, PC104 1076186 CARD, PCI Ethernet, iControl, Prodigy 1000594 SWITCH, keylock, 3 position 1000595 CONTACT block, 1-N.O. and 1-N.C. contact 1036690 PANEL, keypad, iControl...
Page 105 Parts Figure 6-3 Console Parts (2 of 5) Part 1105779-04 E 2014 Nordson Corporation...
Page 106 Description Quantity Note 183418 PLUG, 12 mm, tube 971106 CONNECTOR, male, 12 mm tube x unithread −−−−−− GASKET, manifold, iControl 973442 PLUG, pipe, socket, flush, in. NPT, zinc 984526 NUT, lock, in. conduit 334800 PLUG, in. pipe, 1 in. hex...
Page 107 Parts Figure 6-4 Console Parts (3 of 5) Part 1105779-04 E 2014 Nordson Corporation...
Page 108 See Figure 6-6 for the parts listed in this table: Item Part Description Quantity Note 1023939 PCA, backplane, iControl 982825 SCREW, pan head, recessed, M4 x 12, w/internal lockwasher 320586 RESISTOR, MF, 20K, 1W, 5 AXL 334805 FILTER, line, RFI, power, 10A...
Page 109 110-125 Relay and Fuse Assembly See Figure 6-5 or 6-6 3 POS RECEPTACLE WIRING COLOR BLUE SHIELD WHT/BLU CAN NETWORK CABLE DETAIL GROUND DETAIL POWER SUPPLY DETAIL Figure 6-6 Console Parts (4 of 5) Part 1105779-04 E 2014 Nordson Corporation...
Page 110: Control Relays And Fuses
FUSE, 10.00, fast-acting, 250V 939306 FUSE, 3.15, fast-acting, 250V, 5x20 320586 RESISTOR, MF, 20K, 1W, 5 AXL max.10A max.10A 240V 240V 110−125 110−125 Figure 6-7 Control Relays and Fuses − Console Parts (5 of 5) Part 1105779-04 E 2014 Nordson Corporation...
Page 111: Flow Module Parts
ADAPTER, gun cable, Versa-Spray, porcelain enamel (gray) 334784 ADAPTER, gun cable, Tribomatic CAN Cable Part Description Note 1605395 JACKETED CABLE, twisted pair, shielded, 24 AWG, 120 ohm NOTE A: Order length desired in increments of one foot. Part 1105779-04 E 2014 Nordson Corporation...
Page 112: Junction Boxes, Extension Boxes, And Control Panels
Part Description Note 1039881 KIT, tester, iFlow (air flow verification kit) 1039886 KIT, boost, iControl (flow-rate air flow boost kit for PE spray guns) Recommended Air Filter for Use with iControl Systems Part Description Note 1047526 Filter, gas and compressed air...
Page 113: Conveyor Encoder
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. Photocell and Scanner Cables Part...
Page 114: Software Replacement Kits
Parts Software Replacement Kits Part Description Note 1107154 KIT, software, iControl, Ver. 0.9.26 1107159 S MEMORY, programmed, iControl, Ver. 0.9.26 1034281 S MEMORY, Compact Flash 1107155 KIT, software, iControl, Ver. 2.2.14.2 1107160 S MEMORY, programmed, iControl, Ver. 2.2.14.2 1034281 S MEMORY, Compact Flash 1107156 KIT, software, iControl, Ver.
Page 115 (1098087) (for Nordson positioners) iControl In/Out Positioner/Reciprocator Control Panel (plug-in) (1097160) (for Nordson positioner with reciprocator) iControl Top Down Positioner Control Panel (1092923) (for Nutro-built positioner) iControl Bottom Up Positioner Control Panel (1092924) (for Nutro-built positioner) iControl Top Down Positioner Control Panel (1600011)
Page 116 Wiring and Pneumatic Diagrams Part 1105779-04 E 2014 Nordson Corporation...
Page 117 Reciprocator Speed 3 Phase In Controller 25-Conductor Input Cable Ethernet 100 Meter Length Limit Ethernet Run in one To Booth #2 Run in one common conduit common conduit (Optional) Figure 7-1 iControl System Diagram Part 1105779-04 E 2014 Nordson Corporation...
Page 118: Declaration Of Conformity
DECLARATION of CONFORMITY PRODUCT: iControl Automatic Applicator Controllers for use with Nordson Automatic Spray Applicators APPLICABLE DIRECTIVES: 94/9/EC (ATEX equipment for use in potentially explosive atmospheres) 98/37/EEC (Machinery) 2006/95/EC (Low Voltage Directive) 2004/108/EEC (Electromagnetic Compatibility DIrective) STANDARDS USED FOR COMPLIANCE:...

Nordson iControl Hardware Manual

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