Nordson Encore HD iControl 2 Installation, Troubleshooting, Repair

Integrated control system

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Encore

HD iControl

Integrated Control System

Installation, Troubleshooting, Repair

Customer Product Manual

Document Number

1609758-04

Issued 03/22

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

Table of Contents

Troubleshooting

Summary of Contents for Nordson Encore HD 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 Nordson Corporation welcomes requests for information, comments, and inqui- This is a Nordson Corporation publication which is protected by copyright. ries about its products. General information about Nordson can be found on the Original copyright date 2017. No part of this document may be photocopied,...
Page 3: Table Of Contents
Electrical Connections ........................CAN Network Connections and Settings ..................iControl Console CAN Address and Termination Settings ............Manual Spray Gun Controller Addresses ..................Manual Spray Gun Controller Termination ................... Pump Control Card Addresses ..................... Relay Board ........................... 1609758-04 ©2022 Nordson Corporation...
Page 4 Problems During Calibration ..................... 4-31 Calibration with a Mouse ......................4-32 No Touch Screen Display ......................4-32 Touch Screen Failure ........................4-33 Screens Display, but Touch Function Does Not Work ............... 4-33 No Display ..........................4-33 1609758-04 ©2022 Nordson Corporation...
Page 5 Main/Auxiliary Console Parts (contd) �� Main/Auxiliary Console Parts (contd) �� Pedestal Parts ..........................Options ............................6-10 Miscellaneous Kits ........................6-10 Conveyor Encoder ........................6-10 Photocells and Scanners ......................6-10 Photocell and Scanner Cables ....................6-11 Drawings ............................1609758-04 ©2022 Nordson Corporation...
Page 7 Change Record Change Record Revision Date Change 10/17 New Release. Added Rev 2 Arbor PC to parts list and sections regarding program and data cards. 08/18 Updated wiring diagrams. 02/22 Updated approvals. 03/22 Updated drawings section. 1609758-04 ©2022 Nordson Corporation...
Page 9: Safety
Intended Use Use of Nordson equipment in ways other than those described in the documentation supplied with the equipment may result in injury to persons or damage to property. Some examples of unintended use of equipment include: •...
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. 1609758-04 © 2022 Nordson Corporation...
Page 11: Grounding
• Disconnect and lock out system electrical power. Close hydraulic and pneumatic shutoff valves and relieve pressures. • Identify the reason for the malfunction and correct it before restarting the system. Disposal Dispose of equipment and materials used in operation and servicing according to local codes. 1609758-04 © 2022 Nordson Corporation...
Page 12: Safety Labels
The safety labels are provided to help operate and maintain the console safely. See Figure 1-1 for the location of the safety labels. Table 1-1 Safety Labels Item Part Label Description 1034161 WARNING: Disconnect power before servicing. Figure 1-1 Safety Labels 1609758-04 © 2022 Nordson Corporation...
Page 13: Overview
Hardware Manual: Covers installation, troubleshooting, repair, parts, and drawings for this system only. The Encore HD iControl 2 systems can consist of a main console, an auxiliary console, and a pedestal system. Each system can support up to 32 spray guns.
Page 14: Console And System Hardware And Software
Reciprocators move the spray guns up and down with stroke lengths that vary depending on part size. 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. 1609758-04 © 2022 Nordson Corporation...
Page 15 Figure 2-2 iControl 2 Main Console and Pedestal Internal Components 1. Dual spray gun cards, card cage, 4. I/O board 6. Relay board and backplane 5. PC 7. Power supply − multiple output 2. 24Vdc power supply 3. Touch screen display 1609758-04 © 2022 Nordson Corporation...
Page 16: Operator Interface
In the Lockout position, the spray guns cannot be triggered and the in/out positioners and reciprocators cannot be moved. Use this position when working inside the booth. The lockout can be overridden for the in/out positioners and reciprocators from their configuration screens. 1609758-04 © 2022 Nordson Corporation...
Page 17: Dc Power Supplies
CAN network can also communicate with auxiliary consoles controlling the second booth spray guns. Ethernet Network: Handles communications between the iControl 2 system, the main electrical control panel, and the part ID panel(s). 1609758-04 © 2022 Nordson Corporation...
Page 18: Digital Inputs
(the higher the conveyor speed the coarser the tracking resolution). NOTE: An internal clock or an external timer may be used instead of an encoder. Consult your Nordson representative. 1609758-04 © 2022 Nordson Corporation...
Page 19: Specifications
Maximum Water Vapor in Air Supply: 0.48 grains/ft Moist or contaminated air can cause the HDLV pumps to malfunction; the powder to cake in the reclaim system, or cause clogging in the feed tubing or spray gun powder paths. 1609758-04 © 2022 Nordson Corporation...
Page 20: Special Conditions For Safe Use
2-8 Overview Special Conditions for Safe Use The Encore HD iControl 2 Integrated Controller Main and Auxiliary Consoles and Display Pedestal with Main Console for Pedestal shall be used within the ambient temperature range of +15°C to +40°C with Encore HD Automatic Powder Applicators.
Page 21 Overview 1610723-03 Figure 2-5 Label for Approval (Pedestal Cabinet) Figure 2-6 Label for FM Approval (On Main, Auxiliary, and Pedestal Cabinets) 1609758-04 © 2022 Nordson Corporation...
Page 22: Console Dimensions
2-10 Overview Console Dimensions 611 mm 609.6 mm (24.06 in.) (24 in.) 1634 mm (64.3 in.) 581.5 mm (22.8 in.) Figure 2-7 Console Dimensions 1609758-04 © 2022 Nordson Corporation...
Page 23: Pedestal Dimensions
Overview 2-11 Pedestal Dimensions 386 mm 460 mm (15.2 in.) (18.1 in.) 1385 mm (54.5 in.) 457.2 mm (18 in.) square base Figure 2-8 Pedestal Dimensions 1609758-04 © 2022 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) 1609758-04 © 2022 Nordson Corporation...
Page 25: Introduction
(new, upgrade, or retrofit) and the equipment furnished by the customer. Therefore, this section provides only basic installation information. Detailed information is contained in the system wiring diagrams, plan views, and other documentation furnished by Nordson application engineering. Once all hardware is installed and wired and the system is powered up, the operator interface is used to configure and operate the system.
Page 26: System Connections
Movers Conveyor Motors and Encoder Sensors Main Console with Pedestal ETHERNET Pedestal CAN 1/Lockout AC IN ETHERNET To Pump Panel AC Power OPTIONAL AC Power To Powder Feed Center Figure 3-1 System Interconnect Cable Connections 1609758-04 © 2022 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 pump panels. Optional connection for remote signals for the following functions: • Manual enable • Remote lockout • Alarm relay 1609758-04 © 2022 Nordson Corporation...
Page 28: Electrical Connections
Ethernet Console Ground AC IN Cable Optional Cable CAN to Pump Figure 3-2 Console Rear Panel (Cover Removed) NOTE: For systems with more than 16 spray guns, blank plate replaced with spray gun cable connections. 1609758-04 © 2022 Nordson Corporation...
Page 29: Can Network Connections And Settings
Next Card Manual Gun J-Box Manual Gun Controllers 1-4 BLACK WHT/BLUE Network/Power WHT/BLUE BLUE Cable BLUE WHT/BLUE NOTE: Set Manual Gun BLUE Controller SW1 TERM switch to OFF. SHIELD Figure 3-3 CAN Network Cable Connections 1609758-04 © 2022 Nordson Corporation...
Page 30: Icontrol Console Can Address And Termination Settings
Manual spray gun controllers are shipped with their CAN termination switch set to ON. For each manual spray gun controller in the system: 1. Open the controller enclosure and locate SW1 on the controller interface board. 2. Set the TERM switch on SW1 to OFF. 1609758-04 © 2022 Nordson Corporation...
Page 31: Pump Control Card Addresses
NOTE: The calibration numbers for the HDLV pumps supplying powder to the automatic spray guns must be entered into the iControl configuration. Refer to the iControl Operator Interface manual for instructions. 1609758-04 © 2022 Nordson Corporation...
Page 32: Relay Board
Alarm Input Sig (P2−6) Manual Enable Common Lockout NUIO − Gun Power OK (17HI) Lockout NUIO + Gun Power OK Common Lockout Signal (16HI) Lockout Common Alarm Input from PC + Alarm Input from PC − 1609758-04 © 2022 Nordson Corporation...
Page 33 +12 Vdc Power LED4 +24 Vdc Power Alarm LED5 Conveyor LED7 LED6 Lockout 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 101112131415161718 Figure 3-5 Relay Board 1609758-04 © 2022 Nordson Corporation...
Page 34: Power Connections
Conveyor run AC 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 1609758-04 © 2022 Nordson Corporation...
Page 35: Grounding
Electrostatic discharges occur at very high frequencies, around 100 MHz. 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 Nordson powder coating equipment to protect against ESD.
Page 36: Spray Gun Current Path
(up to 100 kV). The voltage will eventually discharge in a high frequency arc, which can cause damage to the controller electronics (spray gun driver board and power supply). Spray Gun Current Path Ions iControl 2 Ground Braid Figure 3-6 Electrostatic Current Path 1609758-04 © 2022 Nordson Corporation...
Page 37: Esd Ground Procedures And Equipment
Ground Cable Figure 3-7 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. Keep the cables as short as possible.
Page 38: 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. 1609758-04 © 2022 Nordson Corporation...
Page 39: 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. 1609758-04 © 2022 Nordson Corporation...
Page 40: Scanner Cable Connections
ID before the leading edge of the part breaks the zone scanners or photoeyes. SCNR1 PEJB PEJB SCNR2 SCNR1 Single-Zone Scanner Dual-Zone Scanner Part ID Scanner Zone Scanner Part Travel PEJB Part ID and Zone Scanners Figure 3-8 Zone and Part ID Scanner Cable Connections (Typical) 1609758-04 © 2022 Nordson Corporation...
Page 41: Analog Scanner Connections
Refer to Table 3-3 on page 3-14. Use the part ID terminals on the PEJB to connect a customer-supplied part ID system to the iControl 2 console. The eight inputs are used based on the settings made in the Photoeye Configuration screen. Refer to the iControl Operator Interface manual for configuration instructions. 1609758-04 © 2022 Nordson Corporation...
Page 42: Ethernet Network Connections
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. 1609758-04 © 2022 Nordson Corporation...
Page 43 2 System with Main Console System Electrical Control Panel iControl 2 Main Console PLCs Switch Analog Scanner Controllers iControl 2 System with Pedestal iControl 2 Pedestal PLCs Analog Switch Scanner Controllers Figure 3-10 Ethernet Connections 1609758-04 © 2022 Nordson Corporation...
Page 44: Mac Addresses
Cap the unused cable receptacle with the bulkhead seal, then open the console door and unplug the receptacle harness from the spray gun card. Install the jumper in the card receptacle. Refer to the Parts section for seal and jumper part numbers. 1609758-04 © 2022 Nordson Corporation...
Page 45 Installation 3-21 Receptacle #8 Harnesses Bulkhead Seal Jumper Install in #8 Card Receptacle Spray Gun Card Figure 3-11 Seal and Jumper Installation − Example Showing 8-Spray Gun System Using Seven Spray Guns 1609758-04 © 2022 Nordson Corporation...
Page 46: Program And User Data Cards
ETH1 Serial (Touch Screen) (Ethernet) ETH0 (Ethernet) 24 Vdc Power SLOT1 − Program I/O Ribbon Cable Connection VGA (Touch Screen) SLOT2 − Data CAN Network Figure 3-12 iControl 2 Program and User Data Card Slots 1609758-04 © 2022 Nordson Corporation...
Page 47: Touch Screen Calibration
NOTE: Not all CompactFlash cards are the same. When additional cards are purchased, make sure they are from a Nordson-approved manufacturer and are 128 Mb or greater. For approved CF cards, refer to Specifications in the Description section of this manual or contact your Nordson controls engineer or Nordson Technical Support.
Page 48: 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. 1609758-04 © 2022 Nordson Corporation...
Page 49 BLOCK FROM BELOW M5 NUTS GASKET GROUND STUDS DRAIN KIT: AND FASTENERS TUBING, ELBOWS, CLAMPS SUPPLIED WITH A/C UNIT COUPLING BARBED FITTINGS TUBING TO FLOOR DRAIN (CUSTOMER SUPPLIED) Figure 3-13 Optional Air Conditioner Mechanical Installation 1609758-04 © 2022 Nordson Corporation...
Page 50 3-26 Installation A/C UNIT A/C UNIT POWER CORD BROWN CUSTOMER BLUE POWER GREEN/YELLOW CONDUIT/WIRE 200/250 VAC 50/60Hz WIRING HARNESS (INCLUDED WITH KIT) 400W iCONTROL POWER SUPPLY Figure 3-14 Optional Air Conditioner Electrical Wiring Diagram 1609758-04 © 2022 Nordson Corporation...
Page 51: Troubleshooting
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. 1609758-04 © 2022 Nordson Corporation...
Page 52: Error Codes And Alarm Messages
No multiplier load detected. page 4-8 Short circuit detected Multiplier drive circuit shorted. page 4-8 Internal hardware fault Internal DSP fault. page 4-9 detected Spray gun not detected Spray gun not connected to system. page 4-9 Continued... 1609758-04 © 2022 Nordson Corporation...
Page 53 These faults are generated if no resistance is detected, or the correct resistance is not detected. Check the proportional valve wiring connections. Check the solenoid operation. Replace the valve if the solenoid is bad. Continued... 1609758-04 © 2022 Nordson Corporation...
Page 54 Not implemented, future release Copy program failed to start* Not implemented, future release Compare program failed to Not implemented, future release start* Spray gun trigger error* Not implemented, future release Flow/pump trigger error* Not implemented, future release Continued... 1609758-04 © 2022 Nordson Corporation...
Page 55 An illegal address was detected. page 4-15 exception response Illegal Data Value exception An illegal data value was detected. page 4-15 response Slave Device Failure The slave device returned an exception. page 4-15 exception response Continued... 1609758-04 © 2022 Nordson Corporation...
Page 56 − recip mode 1 A vertical scanner is required for variable stroke operation. page 4-25 invalid Speed calculated less than The speed of the reciprocator is less than the minimum value 2107 page 4-26 minimum allowed. Continued... 1609758-04 © 2022 Nordson Corporation...
Page 57: Can Network Errors
CAN errors can also be caused by individual spray 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. 1609758-04 © 2022 Nordson Corporation...
Page 58: Spray Gun Card Troubleshooting
• If the fault changes to E7, check the resistance of the multiplier as detected described in the spray gun manual. • If the fault code stays E8, check the continuity of the cable as described in the spray gun manual. Continued... 1609758-04 © 2022 Nordson Corporation...
Page 59 Trigger ON message The card was commanded to trigger but the system is locked out. Trigger received − ON commands will be ignored until the system is returned to the Run state. − controller in lockout 1609758-04 © 2022 Nordson Corporation...
Page 60: Spray Gun Card Leds
If the card has no power, make sure it is properly seated Lights when power (5 in the backplane and the locking tab is working correctly. Power Green volts) is applied to the Replace the card if the other spray gun control cards have board). power. 1609758-04 © 2022 Nordson Corporation...
Page 61 3. Status LED (green) 6. Power LED (green) processor) 4. Spray Gun Limit B LED (yellow) 7. SW1 (2 position DIP switch for future 2. Fault LED (red) use) 5. Spray Gun Limit A LED (yellow) 1609758-04 © 2022 Nordson Corporation...
Page 62: Air Flow Re-Zero Procedure
9. Remove the plugs from the pattern air output fittings and re-connect the pattern air tubing. 10. At the iControl console, check each spray gun control screen that was previously indicating air flow when the spray gun was off. No air flow should be indicated. 1609758-04 © 2022 Nordson Corporation...
Page 63 Troubleshooting 4-13 Address Switch TEST Button Figure 4-2 Dual Pump Control Board 1609758-04 © 2022 Nordson Corporation...
Page 64: Ethernet Network Troubleshooting
Check Ethernet wiring. Remote node could be disconnected from network or I/O error turned off. Port or socket open error Programming error. Contact Nordson technical support. Serial port already open Programming error. Contact Nordson technical support. Check Ethernet wiring. Remote node could be disconnected from network or TCP/IP connection error turned off.
Page 65 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 successful Normal operation. No action required. −...
Page 66: 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... 1609758-04 © 2022 Nordson Corporation...
Page 67 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... 1609758-04 © 2022 Nordson Corporation...
Page 68 Communication with in/out positioner or reciprocator controller lost during color Clean cycle aborted change cycle. detected machine lockout/ 4111 watchdog fault (Euro color Check the iControl 2 alarm log for Watchdog or TCP/IP faults. Refer to Ethernet change only) Network Troubleshooting on page 4-14. 1609758-04 © 2022 Nordson Corporation...
Page 69 Refer to your system drawings display on iControl 2 for circuit details. screens. If not Nordson USA ColorMax system: Apply jumper to force On the remote disable input. Refer to system drawings for jumper application. Check iControl 2 alarm screen.
Page 70 Ethernet network connections to the controller node, then replace the analog input module. In/Out Positioner preset Normal operating scenario. Position change will only occur when set to Fixed. a new part appears at the in/out positioner. Continued... 1609758-04 © 2022 Nordson Corporation...
Page 71 The first time Auto mode is selected after in/out positioner power up, the in/out positioner moves to the reverse limit switch (home) and acquires a reverse reference value. This value is used to reset the in/out positioner position for Auto operations. Continued... 1609758-04 © 2022 Nordson Corporation...
Page 72 Mechanical failure in connection of in/out Check the mechanical components and connections linking the positioner encoder to encoder ro ation to the movement of the in/out positioner. machine motion. 1609758-04 © 2022 Nordson Corporation...
Page 73: 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... 1609758-04 © 2022 Nordson Corporation...
Page 74 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... 1609758-04 © 2022 Nordson Corporation...
Page 75 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 76: Other Reciprocator Troubleshooting
2 lockout applied to spray guns, This is a normal condition unless a failure has occurred. Refer to in/out positioners, and Photoeye, Encoder, and Interlock Troubleshooting in this section. reciprocators. Continued... 1609758-04 © 2022 Nordson Corporation...
Page 77 Refer to your system drawings (continued) iControl 2 screens. 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. Check iControl 2 alarm screen.
Page 78 “jump” back to it (called hunting). A typical setting is 0.5 − 0.7 inches depending on the reciprocator speed setting. 1609758-04 © 2022 Nordson Corporation...
Page 79: Other Fault Messages And Conditions
Condition: Air flow when gun is not iFlow module proportional valve or solenoid valve stuck open. Refer to the Repair triggered on section for instructions on cleaning the proportional valves. Solenoid valves must be replaced if they do not close. 1609758-04 © 2022 Nordson Corporation...
Page 80: 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. 1609758-04 © 2022 Nordson Corporation...
Page 81: Touch Screen Troubleshooting
If console power is shut off during the calibration procedure: The calibration file on the program card will be corrupted. 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. 1609758-04 © 2022 Nordson Corporation...
Page 82: 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 • 12 Vdc supply to the touch screen • 24 Vdc supply to the PC 1609758-04 © 2022 Nordson Corporation...
Page 83: Touch Screen Failure
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. 1609758-04 © 2022 Nordson Corporation...
Page 85: Repair
Failure to main- tain the dust-tight integrity of the enclosures could invalidate agency approvals and create a hazardous condition. 1609758-04 © 2022 Nordson Corporation...
Page 86: Spray Gun Control Card Removal/Installation
NOTE: Cards are installed in the card cage from left to right. Spray guns are numbered from left to right and bottom to top. 1609758-04 © 2022 Nordson Corporation...
Page 87: Replacing A Card
1 3 5 7 9 11 13 15 Figure 5-1 Spray Gun Control Card Replacement 1. Card cage (slot 1) 3. Spray gun 2 connector 5. Locking tab 2. Gun control card 4. Spray gun 1 connector 6. Backplane 1609758-04 © 2022 Nordson Corporation...
Page 88: Ribbon Cable Connections
Pin 1 Mark (Arrow) PC End iControl 2 PC Ribbon Cable Red or Blue Trace Pin 1 Cable Key Notch I/O Board I/O Board End Pin 1 Mark (Arrow) Figure 5-2 PC−I/O Board Ribbon Cable Connections 1609758-04 © 2022 Nordson Corporation...
Page 89: Touch Screen Replacement
4. Install the replacement touch screen (1) onto the mounting clamp (2) and tighten all mounting nuts (3) to 2.5 N•m (22 in-lb). Pedestal Installation Console Installation Figure 5-3 Touch Screen Replacement 1. Touch screen 2. Mounting clamp 3. Mounting nut 1609758-04 © 2022 Nordson Corporation...
Page 90: Touch Screen Replacement (Contd)
2 Integrated Control System manual. +12V DCOM Figure 5-4 Touch Screen Connections 4. Touch screen terminal block 6. Touch screen serial port 8. Relay board terminal block 5. Video port 7. Power cable harness 1609758-04 © 2022 Nordson Corporation...
Page 91: 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 Part Description Note Main Consoles 1609712 CONTROLLER, Encore HD, iControl 2, 4 gun, main console...
Page 92 CONTROLLER, Encore HD, iControl 2, 26 gun, auxiliary console 1609754 CONTROLLER, Encore HD, iControl 2, 28 gun, auxiliary console 1609755 CONTROLLER, Encore HD, iControl 2, 30 gun, auxiliary console 1609756 CONTROLLER, Encore HD, iControl 2, 32 gun, auxiliary console 1609758-04 © 2022 Nordson Corporation...
Page 93: Interconnect Cables
E. Power and Signals − Main Console to Part ID Junction Box (PD1). F. Power − Main Electrical Control Panel to Auxiliary Console (CA1). G. Extended length replacement for 1603657. H. Extended length replacement for 1603103. 1609758-04 © 2022 Nordson Corporation...
Page 94: Main/Auxiliary Console Parts
NUT, lock, 1/2 in. conduit 334800 PLUG, 1/2 in. Pipe, 1 in. hex 1609937 PLATE, blanking, cable gland, iControl 2 HD NOTE: A. Not used on systems with over 16 spray guns. AR: As Required Continued... 1609758-04 © 2022 Nordson Corporation...
Page 96 D. 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. E. When replacing Arbor PC, order kit 1612971, which includes a Rev 2 Arbor PC and new programmed CompactFlash. AR: As Required Continued... 1609758-04 © 2022 Nordson Corporation...
Page 97 Parts Figure 6-2 Main and Auxiliary Console Parts − Internal Components (2 of 3) 1609758-04 © 2022 Nordson Corporation...
Page 98 • FUSE, 10A, fast-acting, 250 V 334805 FILTER, line, RFI, power, 10A 240976 CLAMP, ground, with wire NOTE: A. One line filter used in auxiliary console. Figure 6-3 Main and Auxiliary Console Parts − Internal Components (3 of 3) 1609758-04 © 2022 Nordson Corporation...
Page 99: Pedestal Parts
NOTE: A. Both the long and short power cable harnesses are provided in the kit. Use the short power cable harness for pedestal installations. B. When replacing Arbor PC, order kit 1612971, which includes a Rev 2 Arbor PC and new programmed CompactFlash. Figure 6-4 Pedestal Parts 1609758-04 © 2022 Nordson Corporation...
Page 100: 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. 1609758-04 © 2022 Nordson Corporation...
Page 101: Photocell And Scanner Cables
Description 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 1609758-04 © 2022 Nordson Corporation...
Page 103: Drawings
Drawings 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 diagrams and schematics. Go to http://emanuals.nordson.com for electronic version of the manual for Encore HD iControl 2 Integrated Control System manual.
Page 111 Product: Encore HD Automatic Powder Spray System This Declaration is issued under the sole responsibility of the manufacture. Models: Encore HD Automatic Applicator and Encore HD iControl 2 Description: This high density, automatic electrostatic powder spray system includes applicator, control cable and associated controllers.
Page 112 Product: Encore HD Automatic Powder Spray System This Declaration is issued under the sole responsibility of the manufacture. Models: Encore HD Automatic Applicator and Encore HD iControl 2 Description: This high density, automatic electrostatic powder spray system includes applicator, control cable and associated controllers.

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