Nordson iControl Series Configuration, Preset Setup, Operation
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Nordson iControl Series Configuration, Preset Setup, Operation

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iControlr Operator Interface
Configuration, Preset Setup, Operation
Customer Product Manual
Part 1056418-07
Issued 9/19
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.
FM
C
US
APPROVED
NORDSON CORPORATION • AMHERST, OHIO • USA

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Summary of Contents for Nordson iControl Series

  • 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. APPROVED 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 2005. No part of this document may be inquiries about its products. General information about Nordson can be...

  • Page 3: Table Of Contents

    ..........3-16 Part 1056418-07 E 2019 Nordson Corporation...
  • Page 4 ..... . . 4-15 Lancing Default Moves Example ..... . 4-16 Part 1056418-07 E 2019 Nordson Corporation...
  • Page 5 ......5-19 Copy Selected: Gun Control Screens ..... . 5-20 Part 1056418-07 E 2019 Nordson Corporation...
  • Page 6 ....8-16 Reciprocator Lap Calculator ......8-17 Part 1056418-07 E 2019 Nordson Corporation...
  • Page 7 ....... . 9-14 Configuration and Preset Records ..... . . 10-1 Part 1056418-07 E 2019 Nordson Corporation...
  • Page 8 Table of Contents Part 1056418-07 E 2019 Nordson Corporation...
  • Page 9 Change Record Change Record Revision Date Change 3/10 Updated for version 3.0 5/10 Updated for version 3.2 4/13 Updated for versions 3.4 and 3.6 09/19 Administrative revision change. Part 1056418-07 E 2019 Nordson Corporation...
  • Page 10 Change Record Part 1056418-07 E 2019 Nordson Corporation...

  • Page 11: Introduction

    Section 1 Introduction This manual covers Configuration, Preset (Recipe) Setup, and Operation of the Nordson iControl and iControl 2 Integrated Control Systems. All tasks described in this manual are accomplished using the iControl Operator Interface. NOTE: This version of this manual covers iControl software up to and including version 3.6.

  • Page 12: Operator Controls

    All setup and operation of the iControl system is done using the Touch Screen, Rotary Dial (iControl only), and Interlock Keyswitch. iControl iControl 2 Interlock Keyswitch Rotary Dial Figure 1-1 IControl and iControl 2 Operator Interfaces Part 1056418-07 E 2019 Nordson Corporation...

  • Page 13: Common Interface Objects And Buttons

    Drop-down Fields: Touch the field Cancel: Touch to cancel changes to open a drop-down list and select or an action, or disable a feature. a value. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 14: Help

    Touching the Top button returns you to the top of the page. Use the scroll bars on the right side of the page to scroll up and down the page. Close Previous Next Home Scroll Bar Figure 1-2 Help Screen Part 1056418-07 E 2019 Nordson Corporation...

  • Page 15: Security System

    A new iControl system, at power up, starts with 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 up users, define their access levels, and create passwords.

  • Page 16: Logging In

    On a new system, touching the Configure button displays the security configuration screen but all functionality is disabled. The security system must be set up by a Nordson Customer Service Representative or engineer. When the CSR logs in the security configuration functionality is enabled.

  • Page 17: Logging Out

    2. User name drop-down 7. Automatic logout timer (minutes) 11. Password 3. Selected user level 8. Enable/disable automatic logout 12. Security level 4. Selected user password 9. Security log 13. User name 5. OK changes Part 1056418-07 E 2019 Nordson Corporation...

  • Page 18: Creating A User

    The timer starts when no activity in the user interface is detected, and the user is logged out when the timer expires. NOTE: Automatic logout is always enabled for Nordson CSRs and Engineers and cannot be changed or disabled for them.

  • Page 19: Viewing The Security Log

    Log. The log file contains a list of user names and the times they logged in and out. Only a Nordson representative can erase the log file. The Erase button is inactive for all other users. Security Levels and Access Rights The following table lists the access rights for all screens and functions.
  • Page 20 Nordson Only − Turn Around Fine Tuning Nordson Only Network Status — Network − Host Configuration Nordson Only Network − Node Configuration Nordson Only Units Data Backup Shutdown 2, 3, 4 About (software versions) — Part 1056418-07 E 2019 Nordson Corporation...

  • Page 21: Standard System Configuration

    Touch Screen Calibration ....... 3-35 Part 1056418-07 E 2019 Nordson Corporation...

  • Page 22: Configuration Flowchart

    Start performed by a user with Level 4 access. Set Units Configure Guns/Input Card Does system have positioners, reciprocators, analog scanners? Log in as Nordson CSR Configure Ethernet Network Configure Positioners Refer to Section 4 Configure Reciprocators Configure Analog Scanners...

  • Page 23: System Configuration Screen

    Prodigy/Encore HD Automatic Guns Pump Purge Configure Calibration Figure 3-2 System Configuration Screen Note: Grayed-out items on your screen require a specific user login, are not applicable to your application, or are features not yet available. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 24: Units Configuration

    HDLV Pump Controller Version I/O Card Spectrum HD Select System Select (EU Only) I/O Card Help Air Flow Upper Limit Manual Mode Lockout Smart Flow Relay Type Mode Enable Figure 3-3 Guns/Input Card Configuration Screen Part 1056418-07 E 2019 Nordson Corporation...

  • Page 25: Default Gun Type

    Limiting the value prevents flow related error messages when the flow settings are too high and the system cannot attain the commanded value. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 26: Smart Flow Mode Enable

    It is recommended that the NC (normally closed) option be used, and all interlocks wired in series, so that any one booth that is offline with its exhaust fan off will break the circuit and prevent manual operation of any booths. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 27: System Restart

    Shut down and reboot 3. Choose Shut down and reboot then touch the OK button. Allow the system to reboot. Refer to Program Shutdown on page 3-33 for a description of the shutdown procedure. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 28: Zone Configuration

    These scanners are typically used only if the system also includes reciprocators, which require them to detect part height, or when an iControl system is retrofitted into an existing system with analog scanners. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 29: Digital Zone Triggering

    As Part 4 moves past the guns, all guns are turned on at the solid sections, and turned off at the open section. Note that guns 1 and 8 stay on for the length of the part. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 30: Analog Zone Triggering

    This drawback also means that the guns in front of an open area of a part will not be triggered off, but will continue to spray. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 31: Configuring Zone Filters

    1 inch filter value fills the gap so that the guns are not triggered off between parts. NOTE: Appropriate lead and lag values should be set for each preset to compensate for the effects of the zone filtering on gun triggering. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 32: Digital Zone Configuration

    NOTE: Selecting PE does not disable an analog scanner if one is present. Analog Zone Configuration Analog scanners must be supplied and configured by Nordson Corporation. NOTE: Before performing the following steps, go to Section 4 and configure the Ethernet network, then configure a vertical analog scanner.

  • Page 33: Configuring The Auto-Zero Function

    Standard System Configuration Configuring the Auto-Zero Function See Figure 3-9. This function is only available to Nordson CSRs. It allows you to tune out a valid signal from Zone 1, such as when you want to ignore part carriers or hangers. This function is not the same as the noise filtering setting explained in Section 4, Analog Scanner Configuration.

  • Page 34: Manual Trigger Lockout

    NOTE: If you change the flagging method you must reboot the system for the change to take effect. Use the Program Shutdown/Reboot procedure (page 3-33) and select Shutdown and reboot on the operating system dialog box. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 35: Straight Flagging

    Part ID 0 (no photoeyes blocked) is not a valid part ID. It is ignored. The following is an example of encoded flagging using a part flag. The table lists the possible part IDs for inputs 1, 2, and 3. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 36: Flag Filter

    5. No beams are broken. Part ID is 0, which is invalid. Flag filter counter is reset and waits for valid part ID before starting. Flag Travel Direction Part ID Filter Length (Travel Distance) Read Input Figure 3-13 Flag Filter Example Part 1056418-07 E 2019 Nordson Corporation...

  • Page 37: Encoder Configuration

    If your system does not have an encoder, or the encoder malfunctions and you do not have a replacement, you can select the CK (clock) option and enter the conveyor speed. This is not as accurate a part tracking method as using an encoder. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 38: Entering A Known Resolution

    If you know your encoder resolution, enter it in the data field in screen box 3, select the Known Resolution radio button, then touch the Enter button. Enter Select Enter Known Known Resolution Resolution Figure 3-15 Entering a Known Resolution Part 1056418-07 E 2019 Nordson Corporation...
  • Page 39 5. The calculated resolution appears in Screen Box 3. Select the calculated resolution radio button, then touch the Enter button. Enter part length Reset counter Calculated resolution Select calculated resolution Enter Figure 3-16 Calculating Encoder Resolution Part 1056418-07 E 2019 Nordson Corporation...

  • Page 40: Fine-Tuning Encoder Resolution

    4. Run the part through the booth. Make sure the gun triggers on at the leading edge of the part and off at the trailing edge. Adjust the encoder resolution as necessary. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 41: Pickoff Configuration

    Enter the length of the booth, from the zone photoeyes or scanners to the end of the booth. This value is used for automatic color change operations to ensure that all parts have cleared the booth before gun purging starts. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 42: Shift Register Reset

    Lead Priority rule is the default selection. Direction of Travel Lead Next Part Previous Part Preset 18 Preset 21 Lead Preset 18 Starts Spraying Here Figure 3-19 Lead Priority Triggering Rule Part 1056418-07 E 2019 Nordson Corporation...
  • Page 43 Preset 18 Preset 21 Lead Preset 18 Starts Spraying Here Direction of Travel Lead Next Part Previous Part Preset 18 Preset 21 Lead Preset 18 Starts Spraying Here Figure 3-21 Split Priority Triggering Rule Part 1056418-07 E 2019 Nordson Corporation...

  • Page 44: Standard Gun Purge Configuration

    Purging is terminated when the purge timer runs out, or a part enters the gap area or spray zone, or when the operator turns off Auto purge by selecting Manual from the Nozzle Purge Control screen. Part 1056418-07 E 2019 Nordson Corporation...
  • Page 45 6. Assign guns to banks by touching the bank field for the gun. Touching the field toggles the bank assignment on or off. Part 1056418-07 E 2019 Nordson Corporation...
  • Page 46 1 Console, 1 Dual Purge Kit: 1 Console, 1 Single Purge Kit: 2 Banks 1 Bank 2 Consoles, 2 Single Purge Kits: 2 Consoles, 2 Dual Purge Kits: 2 Banks 2 Banks Figure 3-24 Bank Configuration Possibilities Part 1056418-07 E 2019 Nordson Corporation...

  • Page 47: Evacuation Purge Configuration

    If the guns are triggered on for a new part before the timer expires, purging immediately stops and the guns start spraying at the preset settings. NOTE: Do not use evacuation purge with Nordson In-Line powder pumps. With these pumps the atomizing air used for purging pumps powder and defeats the purge function.

  • Page 48: Soft Start Configuration

    To use soft start: 1. Enable soft start. 2. Set the ramp timer (0−7.5 seconds, in 0.5 second intervals). EnableSoft Start Disable Soft Start Ramp Timer Figure 3-26 Soft Start Settings Part 1056418-07 E 2019 Nordson Corporation...

  • Page 49: Prodigy/Encore Hd Gun Purge Configuration

    Pulse Off sets the time between pulses. Make settings for the Gun and Siphon Purge Duration and Number of Pulses. The Pulse Cycle On and Off settings apply to both Gun and Siphon pulsing. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 50: Prodigy Hdlv Pump Calibration

    3-30 Standard System Configuration Prodigy HDLV Pump Calibration See Figure 3-28. This function is only available to Nordson CSRs or field engineers. Touching the Pump Calibration button on the System Configuration screen opens the Calibration screen. Each spray gun has its own HDLV pump, located on a pump panel. Inside the panel are the pump control board and manifold.

  • Page 51: Data Backup

    NOTE: Approved cards are SanDisk, Toshiba, PNY, and Memorex 128 Mb (minimum) CompactFlash cards. Do not use unapproved cards. For more information contact your Nordson representative. CAUTION: Do not remove the CompactFlash cards while console power is on. Doing so will corrupt the data on the card.

  • Page 52: Software And Firmware Versions

    When not connected to an external network the address will be 0.0.0.0). If you are calling for technical support, you may be asked for version numbers along with the details of your problem. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 53: Trace

    3-33 Standard System Configuration Trace This button is grayed out unless a Nordson engineer or CSR is logged in. It opens a diagnostic screen that can be used for troubleshooting a system. Program Shutdown The shutdown and reboot procedures shut down all running processes in an orderly sequence and prevent file corruption.

  • Page 54: Desktop Utilities

    CAUTION: Do not make changes or use utilities that are not described in this manual without first consulting with a Nordson controls engineer. Launch: The Launch button opens a menu with the functions that are available on the sidebar.

  • Page 55: Touch Screen Calibration

    Nordson technical support. Configuration: Displays a menu of configuration tools. These tools should only be used with the direction of Nordson technical support. Time/Date: Use this utility to set the time and date. Screensaver: Use this utility to enable or disable the screen saver and power saver.
  • Page 56 The complete procedure times out in 90 seconds. If you do not touch the Completion or Accept button within 10 seconds of pressing the third target the procedure will restart. When you have completed the calibration procedure, touch the iControl button to start the iControl software. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 57: Reciprocator Configuration

    ....4-31 Setting the Zero Offset Override ..... . . 4-32 Part 1056418-07 E 2019 Nordson Corporation...

  • Page 58: Introduction

    Introduction For most configuration tasks you must be logged in as a level 4 user. Some configuration tasks are reserved for Nordson CSRs or engineers. NOTE: The configuration process for positioners and reciprocators includes setting default move settings that apply to all parts. If part-specific settings are required, create positioner and reciprocator presets as described in Sections 6 and 7 of this manual.

  • Page 59: Ethernet Network Configuration

    9, Network and Node Status for information on the Node Status screens and corrective actions for error codes. The CAN Status button opens the CAN Status screen. Your Nordson CSR can use this screen to diagnose problems with the CAN network.

  • Page 60: Host Configuration

    192.162.1.1, the next to 192.162.1.2, and so on up to 192.162.1.5. The software attempts to resolve any address conflicts automatically. LAN Network: This feature is not active at this time. iControl Console Address Customer LAN Settings (Future Release) Figure 4-3 Host Configuration Screen Part 1056418-07 E 2019 Nordson Corporation...

  • Page 61: Node Configuration

    Touch the Node Configuration button on the Network Status screen to open the Node Configuration screen. Security Login: This button opens the Login screen so Nordson CSRs can log in and change settings. 1. Enter the MAC Address, TCP/IP Address, and Machine Type for each node on the network, as described in Table 4-1.
  • Page 62 RC: Reciprocator or Oscillator FC: Feed Center PE: Analog Scanner, used with positioners and reciprocators NOTE: Some machines can have more than one function, such as an in/out positioner and oscillator or reciprocator (GP1_RC1). Part 1056418-07 E 2019 Nordson Corporation...
  • Page 63 Ethernet and Gun Mover Configuration GP4_RC4 GP3_RC3 GP2_RC2 GP1_RC1 Send IP Address Save Login GP1_RC1 GP2_RC2 MAC ADDRESS MACHINE TYPE TCP/IP ADDRESS Figure 4-4 Node Configuration Screen Part 1056418-07 E 2019 Nordson Corporation...

  • Page 64: Positioner Configuration

    14. Retract Position 23. Default Move Settings 5. Off Mode 15. Hysteresis 24. Minimum Move Settings 6. Positioner Selector 16. Encoder Resolution (Nordson 25. Gun to Part Setting Only) 7. Off Lock 26. Lag Setting 17. Lance option 8. Pickoff 27.

  • Page 65: Actual Position

    (0). This position is not the position of the gun tips. Setting Encoder Resolution 1. Log in as Nordson CSR and open the System Configuration screen, then the Positioner Configuration screen. 2. Select a positioner (1−4) and set the positioner mode to OFF.

  • Page 66: Setting Zero And Home Positions

    These settings apply to both horizontal or vertical positioners except where noted. NOTE: Acceleration, deceleration and speed values are fixed and set at the positioner motor speed controller. Only a Nordson engineer should change these values. Manual Positioner Operation: If the positioners will only be operated manually, then the only settings required are to select the Clean Only option and set the Orientation.
  • Page 67 (exhaust fan is shut off), or the network malfunctions. when a color change sequence is started (application specific, consult your Nordson controls engineer). NOTE: The Park/Clean position should not be greater than the distance from the forward limit switch to the reverse limit switch.

  • Page 68: Application-Specific Positioner Configuration Settings

    Default, minimum, and preset move settings are ignored when this option is selected. Positioning Guns on Horizontal Positioners If you need help positioning your guns contact your Nordson representative. For each horizontal positioner: 1. Hang a plumb bob from the conveyor centerline.
  • Page 69 Centerline Offset Positioner (LBB) Gun-to-Conveyor A = Bottom-Up Centerline Offset B = Top-Down A = Bottom-Up With Dual Scanners With Single Scanner B = Top-Down Figure 4-6 Vertical Positioner Configuration (View from Front of Booth) Part 1056418-07 E 2019 Nordson Corporation...

  • Page 70: Move Settings

    Positive lag: Moves the guns AFTER the trailing edge of the part reaches them. Negative lag: Moves the guns BEFORE the trailing edge of the part reaches them. Gun-To-Part Distance to maintain between guns and parts as parts go by guns. Part 1056418-07 E 2019 Nordson Corporation...
  • Page 71 2. Part in front of guns: The positioner follows the contours of the part as the part moves by the spray guns, maintaining the 10-inch gun to part distance (Figure 4-8). Conveyor Centerline Default Gun-to-Part Figure 4-8 Part in Front of Guns: Gun-to-Part Distance Maintained (Top View) Part 1056418-07 E 2019 Nordson Corporation...

  • Page 72: Normal Default Move Example

    −5 inches from the part (5 inches inside the part). Conveyor Centerline Lead: −2 in. Retract Position (Wait Position) Figure 4-10 Part at Lead: Move Forward to Default Gun to Part Distance (Top View) Part 1056418-07 E 2019 Nordson Corporation...

  • Page 73: Lancing Default Moves Example

    Retract position. Conveyor Centerline Lag: −2 in. Retract Position (Wait Position) Figure 4-12 Part at Lead: Move Forward to Default Gun to Part Distance (Top View) Part 1056418-07 E 2019 Nordson Corporation...
  • Page 74 19. Maximum Speed 29. Air Flow Percent Adjust 10. Current Position 20. Turn-Around Offset 30. Speed (No Sync Mode Only) Note: Settings 19, 20, and 21 can only be changed by a Nordson representative. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 75: Encoder Resolution And Maximum Speed

    Nordson Service Settings The encoder resolution, maximum speed setting, and turn-around offset must be set by a Nordson service representative. 1. Log in as Nordson CSR. 2. Select a reciprocator.

  • Page 76: Accel/Decel Time

    Turn-Around Offset field. 10. Adjust the Turn-Around Offset value as necessary until the reciprocator turns around as close to the soft limits as possible. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 77: Standard Reciprocator Configuration Settings

    Position when the Park button is touched. (21) when a color change sequence is started (application specific, consult with your Nordson controls engineer). Spray Pattern Width, in inches or millimeters, of one spray gun fan pattern. If your Width spray gun fan patterns overlap, then enter the average fan pattern (26) width (total fan width of all guns / number of guns).

  • Page 78: Application-Specific Reciprocator Settings

    Shorter strokes will result in larger errors because the machine does not have sufficient time running at full speed. Figure 4-15 Reciprocator Speed Settings Part 1056418-07 E 2019 Nordson Corporation...

  • Page 79: Fixed Mode

    Guns On Downstroke Guns Off Upstroke Top Turn-Around Limit Bottom Turn-Around Limit Guns Off Downstroke Guns On Upstroke Reciprocator Speed (Used for Fixed No Sync mode only) Figure 4-16 Fixed Mode Settings Part 1056418-07 E 2019 Nordson Corporation...

  • Page 80: Oscillator Mode

    They are measured from Reciprocator Home. Set the top turn-around limit below the soft top limit value, and the bottom turn-around limit above the soft bottom limit value. Part 1056418-07 E 2019 Nordson Corporation...
  • Page 81 Figure 4-19 Variable Mode Settings Variable Mode: Overtravel Settings Positive, Extended Pattern Reciprocator Home (0) Top Soft Limit Top Turn-Around Top Overtravel Bottom Overtravel Bottom Turn-Around Bottom Soft Limit Figure 4-20 Variable Mode: Overtravel Settings Positive, Extended Pattern Part 1056418-07 E 2019 Nordson Corporation...

  • Page 82: Air Flow Percent Adjust Control

    Reciprocator in the Standard Reciprocator Configuration Settings table on page 4-21. NOTE: Percent Adjust is an additive variable. These Percent-Adjust settings are added or subtracted from Reciprocator Preset Percent Adjust settings, Global Percent-Adjust settings, and Conveyor Speed Percent-Adjust settings. Part 1056418-07 E 2019 Nordson Corporation...
  • Page 83 4-27 Ethernet and Gun Mover Configuration Enable Stroke Length Flow-Rate Air Atomizing Air Stroke Length Flow-Rate Air Atomizing Air Figure 4-22 Air Flow Percent Adjust Control Screen Part 1056418-07 E 2019 Nordson Corporation...

  • Page 84: Analog Scanner Configuration

    2. Enter the number of horizontal scanners (1 or 2). 3. Touch the scanner Configure button to open the Scanner Configuration screen. Enable/ Disable Number of Horizontal Scanners Configure Figure 4-23 Enabling and Selecting Number of Horizontal Scanners Part 1056418-07 E 2019 Nordson Corporation...

  • Page 85: Single In/Out Positioner Scanner Configuration

    B: The width of the conveyor left and right of the scanner centerline. C: Distance from the first scanner beam (cable end) to the conveyor centerline. Figure 4-24 SIngle Scanner Configuration for In/Out Positioners Part 1056418-07 E 2019 Nordson Corporation...

  • Page 86: Dual In/Out Scanner Configuration

    E: Vertical offset − This is the distance from the zero position of the spray guns on a reciprocator to the topmost beam of the scanner. For up/down positioners set this value to 0. For reciprocators, refer to Vertical Offset and Figure 4-27 for a detailed explanation. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 87: Vertical Offset (Reciprocators Only)

    The Vertical Offset should be negative if the 0 channel of the scanner (topmost beam) is above the gun 0 position. This causes the scanner area above the gun 0 position to be ignored and reduces the length of the scanner by the offset. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 88: Setting The Zero Offset Override

    5−20 units larger than what it takes to display 0. For example, if when a phantom part is detected the LBB value is 125, then enter a value from 130−150 in the LBB field. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 89: Spray Gun Preset Settings

    When the system is operating in Automatic Part ID mode, a part with an ID number of 2 is sprayed with preset 2 settings. Although all guns spray the part using the same preset, the settings for the preset can be different for each gun. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 90: Spray Gun Preset Screens

    To copy your settings, use Copy All (8) or Copy Selected (10). Refer to the explanations starting on page 5-15. The Keypad button (9) opens a keypad that you can use to enter settings. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 91: Spray Gun Preset Table Screen

    Copy All button. To save your settings, touch the Save button. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 92: Preset Number And Name

    Preset Number field and use the rotary dial. To give a preset number a name, touch the Preset Name field. The keyboard screen opens. Use the keyboard to type in a preset name that allows you to easily identify your parts. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 93: Air Flow Settings For Venturi Pumps

    NOTE: The air flow settings in the tables will provide slightly more powder to the spray guns when applied to a Nordson Modular powder pump and slightly less powder when applied to a Nordson In-Line powder pump. Atomizing Air...

  • Page 94: Pressure To Flow Conversion Tables

    2.48 (36.0) 4.62 (2.75) 2.65 (38.5) 4.62 (3.75) 2.86 (41.5) 5.04 (3.00) 2.96 (43.0) 5.04 (3.00) 3.21 (46.5) 5.52 (3.25) 3.31 (48.0) 5.52 (3.25) 3.52 (51.0) 5.96 (3.5) 3.59 (52.0) 5.69 (3.35) 3.65 (53.0) Part 1056418-07 E 2019 Nordson Corporation...

  • Page 95: Smart Flow Settings For Venturi Pumps

    The Smart Flow tables provide a range of possible Total Flow and Flow Air % setpoints. Read across to the vertical axis for the equivalent atomizing air flows and pressures. Read down to the horizontal axis for the equivalent flow-rate air flows and pressures. Part 1056418-07 E 2019 Nordson Corporation...
  • Page 96 Max Flow Increase velocity, no change in flow 50% Flow Air % Setpoint 3.00 Total Flow Setpoint Increase flow, no change in velocity Max Velocity Figure 5-7 Reading the Smart Flow Tables Part 1056418-07 E 2019 Nordson Corporation...

  • Page 97: Smart Flow Settings − Metric Units

    6.37 6.79 7.22 7.64 8.07 8.49 8.92 9.34 9.77 10.19 5.95 6.80 7.22 7.65 8.07 8.50 8.92 9.35 9.77 10.20 0.85 1.27 1.70 2.12 2.55 2.97 3.40 3.82 4.25 4.67 5.10 5.52 5.95 Flow Part 1056418-07 E 2019 Nordson Corporation...

  • Page 98: Smart Flow Settings − English Units

    4.00 4.25 4.50 4.75 5.00 5.25 5.50 5.75 6.00 3.50 4.00 4.25 4.50 4.75 5.00 5.25 5.50 5.75 6.00 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00 3.25 3.50 SCFM Flow Part 1056418-07 E 2019 Nordson Corporation...

  • Page 99: Prodigy/Encore Hd Air Flow Settings

    3. Adjust the settings while observing the spray pattern and by bagging and weighing the powder. To set Powder Flow and Pattern Air Flow, touch the flow button, then use the slider bar or rotary dial. Only one setting can be made at a time. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 100: Electrostatic Settings

    Select Coat Mode 4 (User). For Tribomatic guns, only the AFC setting is available. It is used to set the current feedback alarm level. AFC Setting kV Setting Select Charge Mode Figure 5-10 Electrostatic Settings Part 1056418-07 E 2019 Nordson Corporation...

  • Page 101: Setting Kv

    Select Charge mode is not used with Tribomatic guns. Touching the Select Charge button repeatedly toggles through the modes. The icon next to the button indicates the mode setting. Mode icons and descriptions of each mode are described in the following tables: Part 1056418-07 E 2019 Nordson Corporation...
  • Page 102 100 kV 15 μA Special not adjustable 60 kV 60 kV 30 μA Deep Cavity, gun not adjustable 95 kV 100 kV 70 μA inside User Programmable adjustable 60 kV 60 kV 30 μA Part 1056418-07 E 2019 Nordson Corporation...

  • Page 103: Lead And Lag Settings

    A negative lag value turns off the spray guns BEFORE the trailing edge passes them (Restricted Spray). Gun Control Screen Conveyor Direction Lead Leading Trailing Edge Edge Preset Table Screen Lead − − Lead Gun ON Gun OFF Figure 5-11 Lead and Lag Settings Part 1056418-07 E 2019 Nordson Corporation...

  • Page 104: Perfect Pickoff Example

    BEFORE the leading edge of the part reaches the guns, and stop spraying 5 units AFTER the trailing edge of the part passes the gun. Lag = 5 Lead = 5 Conveyor Direction Gun Off Gun On Figure 5-13 Extended Spray Part 1056418-07 E 2019 Nordson Corporation...

  • Page 105: Restricted Spray Example

    BEFORE the leading edge of the part reaches the guns, and stop spraying 3 units BEFORE the trailing edge of the part reaches the guns. Lead = 5 Lag = −5 Conveyor Direction Gun On Gun OFF Figure 5-15 Extended-Restricted Spray Part 1056418-07 E 2019 Nordson Corporation...

  • Page 106: Zone Assignment

    To prevent a spray gun from triggering for a particular part, set the zone assignment to zero for the preset. The gun will not be triggered when that part passes by. Gun Control Screen Conveyor Direction Zone Preset Table Screen Zone Zones Guns Figure 5-16 Zone Assignments Part 1056418-07 E 2019 Nordson Corporation...

  • Page 107: Copy All: Gun Control Screen

    Save button. Close the screen and touch the Cancel button on the dialog that asks if you want to save your changes. Selected Settings Copy All Save Figure 5-18 Copy All: Preset Table Screen Part 1056418-07 E 2019 Nordson Corporation...

  • Page 108: Copy Selected: Gun Control Screens

    4. Press the Copy button to start copying. 5. When the copy operation is complete, the screen closes automatically. Copy Selected Destination Guns Selected Source Settings Destination Presets Source Guns Source Presets Copy Copy Start Figure 5-19 Zone Assignments Part 1056418-07 E 2019 Nordson Corporation...

  • Page 109: Positioner Preset Settings

    Refer to Section 5, Positioner/Reciprocator Configuration for more information on default and minimum settings. In/Out Positioner Settings: lead and lag move points gun to part distance (variable) gun position (fixed) Part 1056418-07 E 2019 Nordson Corporation...
  • Page 110 When a part with a fixed position setting arrives, the positioner moves to the fixed position and remains there until a new part arrives with either: no preset move settings (default settings are used) or different preset move settings. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 111: Copying Preset Settings

    Reset to Defaults The Reset button clears the values in the selected preset. The positioner will then use the configured default values for that preset. Refer to Positioner Configuration in Section 4. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 112: Using Preset Settings

    Refer to Positioner Configuration in Section 4 to make minimum and default lead, lag, and gun-to-part settings. These examples illustrate the most common move sequences. Contact your Nordson representative if your need help setting up move sequences. NOTE: Preset settings override default settings. Minimum settings override the preset settings.

  • Page 113: Variable Positioning − Contouring

    5. Four inches after the trailing edge of the part, the guns are moved forward to wait for the next part. Lead Lead Steps Figure 6-3 Variable Positioning − Contouring Part 1056418-07 E 2019 Nordson Corporation...

  • Page 114: Variable Positioning − Lancing And Contouring

    5. Four inches after the trailing edge of the part passes the trailing gun, the positioner moves back to the Retract position to wait for the next part. G−P G−P G−P Lead Lead Steps Figure 6-4 Variable Positioning − Lancing and Contouring Part 1056418-07 E 2019 Nordson Corporation...

  • Page 115: Variable Positioning − Lancing Into Deep Recesses

    5. At the default lag (5 in. AFTER the trailing edge) the guns are moved in to wait for the next part. G−P G−P G−P Lead+ Lag + Lag − Lead − Preset Preset Default Default Steps Figure 6-5 Variable Positioning − Lancing into Deep Recesses Part 1056418-07 E 2019 Nordson Corporation...
  • Page 116 Positioner Preset Settings Part 1056418-07 E 2019 Nordson Corporation...

  • Page 117: Reciprocator Preset Settings

    Reciprocator Settings: spray gun trigger on/off up/down points (fixed mode) reciprocator turn-around points (fixed and variable modes) reciprocator speed (fixed and variable) reciprocator overtravel distances (variable) flow-rate and atomizing air percent adjust Part 1056418-07 E 2019 Nordson Corporation...

  • Page 118: Copying Preset Settings

    Reset to Defaults The Reset button clears the values in the selected preset. The reciprocator will then use the configured default values for that preset. Refer to Reciprocator Configuration in Section 4. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 119: Fixed Mode Settings

    Reciprocator Speed can be set for both Fixed, No Synchronization and Variable, No Synchronization modes. If the mode is Synchronized, then the speed is controlled by the conveyor speed and other configuration settings and cannot be set for presets. Part 1056418-07 E 2019 Nordson Corporation...
  • Page 120 Top Turn-Around Fixed Mode Positive On/Off Settings Extended Spray Bottom Turn-Around Reciprocator Home (0) Conveyor Travel Top Turn-Around Fixed Mode Negative On/Off Settings Restricted Spray Bottom Turn-Around Figure 7-2 Reciprocator Preset Settings − Fixed Mode Part 1056418-07 E 2019 Nordson Corporation...

  • Page 121: Variable Mode Settings

    Bottom Turn-Around (Configuration Setting) Reciprocator Home (0) Conveyor Travel Top Turn-Around (Configuration Setting) Top Overtravel Variable Mode Negative Overtravel Settings Restricted Spray Bottom Overtravel Bottom Turn-Around (Configuration Setting) Figure 7-3 Reciprocator Preset Settings − Variable Mode Part 1056418-07 E 2019 Nordson Corporation...

  • Page 122: Reciprocator Preset Percent-Adjust Settings

    % On Off Up % On % On % On Off Down % Off % Off % Off On Up % Off Variable Mode Fixed Mode Figure 7-4 Reciprocator Preset Settings − Variable Mode Part 1056418-07 E 2019 Nordson Corporation...

  • Page 123: Operation

    ....8-16 Reciprocator Lap Calculator ......8-17 Part 1056418-07 E 2019 Nordson Corporation...

  • Page 124: Screen Icons

    /hr) Pattern air flow (scfm or m /hr) (Prodigy guns only) Assist Air Preset Compensation (Prodigy guns only) Voltage (kilovolts) Zone Microamperes Part ID (current) Trigger or Operation Modes Automatic Manual Trigger Switch (Toggle) Part 1056418-07 E 2019 Nordson Corporation...

  • Page 125: System Startup

    You must turn the booth exhaust fan on first. Conversely, if the booth exhaust fans are shut off first, then turning the switch to the lockout position has no effect. Figure 8-1 Lockout Notice Part 1056418-07 E 2019 Nordson Corporation...

  • Page 126: Main Screen Operating Functions

    6. Positioner preset screen 14. Global control screen 22. Reciprocator preset screen 7. System configuration screen 15. Part ID name and number 23. Reciprocator control screen 8. Scroll right 16. Part ID control screen Part 1056418-07 E 2019 Nordson Corporation...

  • Page 127: Global Mode Controls

    Preset Selector Manual Trigger Toggle Figure 8-4 Global Control Screen − Manual Preset and Trigger Control NOTE: To control a single gun manually, use the Gun Control screen for that gun. Refer to page 8-11. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 128: Part Id Control

    8, you must do it manually using Global Manual Triggering (page 8-5). Straight flagging only allows Part IDs from 1−8. Any preset number greater than 8 will be forced to 8. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 129: Purge Controls

    NOTE: Purging of HDLV systems is part of the booth/gun cleaning function. Manual purging should not be used outside of the cleaning operation. Touch the Purge Control button to open the Purge Control screen. The screen that opens depends on the purge configuration. Part 1056418-07 E 2019 Nordson Corporation...
  • Page 130 3. When you touch the OK button, the Purge Control screen reappears. The Purge Counter counts up until the purge is complete. 4. Stop a purge sequence at any time by touching the Purge Trigger button again. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 131: Percent Adjust Functions

    Setting the values to zero turns Global Percent Adjust off. The Percent Adjust Limit prevents the additive effect from increasing the flow-rate and atomizing air percent adjust beyond the value entered. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 132: Conveyor Speed Percent Adjust

    Enable/ Atomizing Air Disable or Pattern Air Speed % Flow % Adjust Limit Fast % Atomizing Air or Pattern Air Nominal Conveyor % Adjust Slow Dead Band % Speed Figure 8-8 Percent Adjust Screen Part 1056418-07 E 2019 Nordson Corporation...

  • Page 133: Spray Gun Controls

    3. To trigger the gun manually, change the gun’s trigger mode to Manual, then touch the Manual Trigger button to trigger the gun on. Touch the button again to trigger the gun off. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 134: Turning Individual Guns On And Off

    Gun buttons for the desired guns and change their operating mode to Manual or Off. To return all guns to operation, touch the Global Operation Mode button on the Main screen, then touch the Auto mode button. Refer to Global Controls on page 8-5. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 135: Positioner Controls

    When locked out, it cannot be operated from this control screen or by an external signal. WARNING: Whenever making adjustments or repairs to a positioner or reciprocator, always disconnect power, then tag and physically lock out the power source. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 136: Positioner Homing And Startup Sequence

    Mode Indicator Main Screen Gun to Retract Positioner Buttons Centerline Position Auto Manual Lock Manual Current Off Lock Position Lockout Indicator Figure 8-10 Positioner Control Screen Part 1056418-07 E 2019 Nordson Corporation...

  • Page 137: Reciprocator Controls

    Home: Touching the Home button moves the reciprocator to the Home position, which is 1.0 inch off the top limit switch. Top and Bottom Soft Limits: These are set during Reciprocator Configuration. They prevent the reciprocator from tripping the top and bottom limit switches. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 138: Default And Preset Setting Adjustments

    Fixed or Variable. Figure 8-12 lists the settings. The settings can be adjusted as desired. NOTE: If the reciprocator mode is synchronized with conveyor speed (green conveyor in mode icon) then the reciprocator speed cannot be adjusted. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 139: Reciprocator Lap Calculator

    Touching the Lap Patterns provides access to the Lap Pattern screens, the first shows the lap pattern without fan width data; the other shows the lap pattern with the fan width included. Part 1056418-07 E 2019 Nordson Corporation...
  • Page 140 Stroke Length Conveyor Speed Overtravel Speed Number of Laps Cycles/Minute Part Height Automatic Manual Spray Pattern Width Calculate Lap Pattern Time Time Lap Pattern with Fan Width Lap Pattern Only Figure 8-13 Reciprocator Lap Calculator Part 1056418-07 E 2019 Nordson Corporation...
  • Page 141 Cycles per minute A cycle is defined as complete when the guns return to their start position. Number of up and down cycles per minute resulting from settings. Part 1056418-07 E 2019 Nordson Corporation...
  • Page 142 8-20 Operation Part 1056418-07 E 2019 Nordson Corporation...

  • Page 143: Monitoring Operation

    ....... . . 9-14 Part 1056418-07 E 2019 Nordson Corporation...

  • Page 144: Gun Monitoring

    If a gun control card, iFlow module, or pump control card goes offline or stops communicating with the iControl PC, the Network Error Indicator appears on the screen next to the gun and preset number. Touching the Global Hourmeter button opens the Global Hourmeter screen. Part 1056418-07 E 2019 Nordson Corporation...
  • Page 145 Monitoring Operation Preset Global Status Bar Graph Legend Atomizing Air (Standard Guns) Pattern Air (Prodigy Guns) Scroll Consoles/ Guns Global Hourmeter Network Error Indicators Figure 9-1 Global Status Screen Part 1056418-07 E 2019 Nordson Corporation...

  • Page 146: Global Hourmeter

    When the required maintenance is complete, reset the timer by touching the gun reset button. Pumps Guns Hours On Timer Reset Total Hours On Maintenance Timer Figure 9-2 Global Hourmeter Part 1056418-07 E 2019 Nordson Corporation...

  • Page 147: Single Gun Status

    (also for Prodigy pumps). gun and pump total hours. Gun and pump maintenance hours are reset from the Configure Hourmeter screen. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 148: Part Id

    They indicate which zones the part occupies. The Part Height is displayed when an analog scanner is used to detect part height. The Part ID Indicators light when they receive a part ID signal. The Part ID Number is displayed below the indicators. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 149: Color Change Monitoring

    1. Request Clean Cycle from positioner 1: Display cleaning icon. 2. Clean Cycle pending: Indicator 1 lights green. Waiting for parts to exit the booth. 3. Clean Cycle ready: Indicator 2 lights green. Purge permission sent to all positioners. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 150: Alarms

    Refer to the Troubleshooting section of your console hardware manual for an explanation of the fault codes and suggested methods to correct the faults. Contact your Nordson representative or call the Finishing Customer Support Center at 800-433-9319 for help. Alarm Screen The Alarm Button blinks yellow if a fault occurs.

  • Page 151: Alarm Log

    CAN messages when the system is configured to not log them into the normal Alarm log. Additional files may be listed. The information in these log files may be used by Nordson field engineers or technical support staff.
  • Page 152 9-10 Monitoring Operation Close Alarm Log Alarm Log Dropdown Menu Delete Open Log Help From Alarm Screen Cancel Delete Alarm Log Contents Confirm Delete Figure 9-9 Alarm Log Screen Part 1056418-07 E 2019 Nordson Corporation...

  • Page 153: Network Status

    NOTE: Only configured nodes will have a button on this screen. Touching a Node Status Button opens the Status screen for that node. See Figure 9-11. This screen is used for diagnosing problems with the network and the nodes. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 154: Node Status Codes

    9-12 Monitoring Operation Figure 9-11 Node Status Screen Node Status Codes Type Code Description In/Out Positioner Booth Part ID Feed Center Layout Code Description GM1_GM2 GM3_GM4 RC1_RC2 RC3_RC4 GM1_RC1 GM2_RC2 GM3_RC3 GM4_RC4 NO ENTRY Part 1056418-07 E 2019 Nordson Corporation...

  • Page 155: Node Error Codes

    Errors 65, 68: Check Ethernet connections. Usually means controller is unplugged or off. Errors 66, 67, 69−75: Programming errors. Call Nordson Technical Support. Errors 129−132: Noise on circuit. Check connections. Check to ensure Ethernet cables are not parallel to high voltage or VFDs.

  • Page 156: Can Network Errors

    Alarm screen. Enabling the alarms will cause them to appear on the Alarm screen. The CAN alarm and CAN status log file lists all the CAN messages that would normally be in the Alarm log. Up to 5 days of logs are maintained. Part 1056418-07 E 2019 Nordson Corporation...

  • Page 157: Configuration And Preset Records

    NOTE: When you are finished configuring your system and setting up your presets, you should immediately make a backup of the user data card and store the duplicate card in a save place. Refer to Data Backup on page 3-31 for instructions. Part 1056418-07 E 2019 Nordson Corporation...
  • Page 158 Width of Conveyor from Scanner CL Left: Right: Vertical Analog Scanner Length of Scanner: Vertical Offset (zero position of guns to top beam of scanner): Scanner Beam Resolution: 3/8 in. 3/4 in. Zero Offset FBB: LBB: Part 1056418-07 E 2019 Nordson Corporation...
  • Page 159 Bank 1 Guns: Bank 2 Guns: Number of Pulses (0−99): Siphon Purge Bank 3 Guns: Duration (1−10 secs): Bank 4 Guns: Number of Pulses 0−99): Pulse Cycle Pulse On (0.1−1.0 secs): Pulse Off (0.1−1.0 secs): Part 1056418-07 E 2019 Nordson Corporation...
  • Page 160 10-4 Configuration and Preset Records Gun Pickoff and Purge Bank Record Date: System: Console (A or B) Gun Number Pickoff Purge Bank No. Part 1056418-07 E 2019 Nordson Corporation...
  • Page 161 Date: System: Remote I/O Network Mask: LAN Network Mode: Mask: Gateway: Name: Domain: Node Configuration Device TCP/IP Machine Type Machine Types GP: Gun Positioner RC: Reciprocator PE: Analog Scanner GP1_RC1: Gun Positioner1_Reciprocator1 or Oscillator1 Part 1056418-07 E 2019 Nordson Corporation...
  • Page 162 Gun to Centerline: Park/Clean Position: Retract Position: Hysteresis: Pickoff: Minimum Lead: Minimum Lag: Minimum Gun-to-Part Distance: Default Lead: Default Lag: Default Gun-to-Part Distance: Lance (Y/N)? USA ColorMax (Y/N)? Y-Axis (Y/N)? No Drive (Y/N)? Clean Only (Y/N)? Part 1056418-07 E 2019 Nordson Corporation...
  • Page 163 Variable, Not Synchronized Oscillator Default Fixed Settings Guns On Downstroke: Guns Off Upstroke: Top Turn-Around: Bottom Turn-Around: Guns Off Downstroke: Guns On Upstoke: Speed: Default Variable Settings Top Overtravel: Top Turn-Around: Bottom Turn-Around: Bottom Overtravel: Speed: Part 1056418-07 E 2019 Nordson Corporation...
  • Page 164 Reciprocator Reciprocator Reciprocator Flow-Rate 0−7.9 Atomizing Flow-Rate 8−15.9 Atomizing Flow-Rate 16−23.9 Atomizing Flow-Rate 24−31.9 Atomizing Flow-Rate 32−39.9 Atomizing Flow-Rate 40−47.9 Atomizing Flow-Rate 48−55.9 Atomizing Flow-Rate 56−63.9 Atomizing Flow-Rate 64−71.9 Atomizing Flow-Rate 72 + Atomizing Part 1056418-07 E 2019 Nordson Corporation...
  • Page 165 10-9 Configuration and Preset Records Spray Gun Preset Settings System: Date: Preset No: Preset Name: Flow-Rate Air Atomizing Air Select Charge (Powder Flow) (Pattern Air) Mode Lead Zone Part 1056418-07 E 2019 Nordson Corporation...
  • Page 166 Positioner Preset Settings System: Date: Preset No: Preset Name: Fixed / Variable Fixed Positioner Lead Variable Position Position Positioner Preset Settings System: Date: Preset No: Preset Name: Fixed / Variable Fixed Positioner Lead Variable Position Position Part 1056418-07 E 2019 Nordson Corporation...
  • Page 167 Guns On Up: Top Turn-Around: Bottom Turn-Around: Speed: Variable Settings Speed: Top Overtravel: Bottom Overtravel: Percent Adjust Settings % On Up: % Off Down: % On Down: % Off Up: % Adjust Flow-Rate: % Adjust Atomizing: Part 1056418-07 E 2019 Nordson Corporation...
  • Page 168 10-12 Configuration and Preset Records Part 1056418-07 E 2019 Nordson Corporation...

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