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General| Brand | Nordson |
|---|---|
| Model | iControl Series |
| Category | Recording Equipment |
| Language | English |
Description of Nordson iControl systems for automatic spray guns.
Details on Prodigy and Encore HD iControl systems controlling up to 32 spray guns.
Reference to manuals for iControl hardware specifications, installation, and wiring diagrams.
Explanation of how to use the iControl operator interface for system configuration and operation.
Explanation of touch screen interaction and rotary dial usage for settings and navigation.
Description of the three positions of the interlock keyswitch: Ready, Lockout, and Conveyor Bypass.
How to open the Help screen from the Main screen and use navigation links.
Explanation of navigation buttons (Previous, Next, Home, Top) and scroll bars in the Help screen.
Explains the initial state of the security system and how to enable user access.
Details on the Log In/Log Out screen and the Configure button's availability.
Security system must be set up by a Nordson Representative or engineer.
Step-by-step guide on how to log in to the iControl system using user name and password.
Procedure for logging out of the iControl system and the automatic logout timer.
Details on the security configuration screen for managing users, levels, and passwords.
Instructions for creating new user accounts with name, level, and password.
How to edit existing user accounts or delete them using the configuration screen.
How to access and view the security log containing user login and logout times.
Table detailing access rights for screens and functions based on user security levels.
A flowchart guiding the user through the system configuration process in the correct order.
Description of the main system configuration screen and its various modules.
Explanation of the configuration flowchart for setting up the system in the correct sequence.
Note that most configuration tasks require Level 4 user access.
How to open the System Configuration screen from the Main screen button.
Detailed look at the System Configuration screen, its modules and important notes regarding features.
Configuration of measurement units like Inches or Millimeters.
Settings for guns, input cards, and conveyor indicator.
Explanation of the functions available on the Guns/Input Card Configuration screen.
Settings for default gun type, HDLV pump controller version, and Spectrum HD.
Configuring the number of guns per console and setting the flow air upper limit.
Enabling Smart Flow mode and selecting digital input cards.
Explanation of the manual mode lockout feature to prevent accidental gun triggering.
Steps required to restart the iControl system after configuration changes.
Choosing 'Shut down and reboot' to restart the system after applying changes.
Introduction to zone configuration for detecting parts and triggering guns.
Explanation of digital and analog zone inputs for scanner configuration.
Table showing how guns are assigned to zones for triggering.
Examples illustrating digital zone triggering for different part configurations.
Illustration of digital zone triggering with an open part on the conveyor.
How to use analog scanners for zone detection and their limitations.
How to configure zone filters to adjust part length detection for triggering.
Using negative filter values to prevent hanger skip and positive values to extend part length.
Configuring digital zones by selecting PE radio button and number of zones.
Detailed steps for configuring analog scanners for zone detection.
Configuring auto-zero for signals to ignore carriers or hangers.
Using zone inputs for direct triggering of spray guns by an external controller.
Using zone inputs for direct triggering and manual trigger lockout with input 23.
Setting up part ID inputs using flagging methods and filters.
Explanation of Straight Flagging for Part ID detection, limiting to 8 Part IDs.
Explanation of Encoded Flagging for Part ID detection, identifying up to 255 Part IDs.
Example of encoded flagging using a part flag and binary codes.
How the flag filter works to prevent false part ID readings by measuring travel distance.
Configuring conveyor encoder signal, resolution, and selecting clock option.
Options for multiplying or dividing encoder pulses for finer or coarser resolution.
Formula and examples for calculating correct encoder scale using the internal clock.
Steps to enter a known encoder resolution value for conveyor speed.
Procedure for the iControl system to automatically calculate encoder resolution.
Steps for resetting the counter and entering the part length for calculation.
Adjusting encoder resolution for optimal accuracy and triggering, potentially needing mechanical adjustments.
Steps for fine-tuning encoder resolution by adjusting pickoffs and checking gun triggers.
Configuring pickoff distances from scanners to guns for each spray gun.
Setting the length of the booth for automatic color change and purging operations.
Using shift register reset to clear track if conveyor direction is reversed.
Explanation of the default Original Triggering Rule and its potential for erratic triggering.
Mandates lead of next part starts after trailing edge of previous part if overlap.
Rules that manage lag continuation or split priority for overlapping parts.
Overview of standard gun purge configuration including nozzle purge.
Configuration for Versa-Spray nozzle purge using high air pressure.
Steps to enable nozzle purging by touching the radio button next to the check mark.
Configuring purge time, delay, line gap, and assigning guns to banks.
Enabling evacuation purge and setting purge timer and air flow.
Notes on evacuation purge operation, including incompatibility with In-Line powder pumps.
How soft start minimizes powder surging when guns are triggered.
Enabling soft start and setting the ramp timer for gradual flow increase.
Explanation of the gun purge sequence for Prodigy/Encore HD guns.
Setting purge duration, number of pulses, and pulse cycle times.
Calibration procedure for Prodigy HDLV pumps, requiring CSR or engineer access.
Entering calibration numbers from the pump manifold label into the calibration screen.
Instructions for backing up user data using the Data Backup utility and system shutdown.
Information on approved CompactFlash cards and precautions for card removal.
Diagram showing locations of Compact Flash card adapters.
How to check iControl software and firmware versions and console IP address.
The Trace button is available for troubleshooting when an engineer or CSR is logged in.
The shutdown confirmation screen prompting to confirm the shutdown process.
Accessing the desktop after shutdown to use utilities and change settings.
Choosing between Logout, Shut down system, or Shut down and reboot from the dialog box.
Explains utilities like Sys Restart, Utilities, Configuration, Time/Date, Screensaver, Network, Calib, System Monitor.
How to start the touch screen calibration process by touching the CAL or CALIB button.
Notes on previous vs. new calibration procedures requiring touch and hold.
What happens if calibration instructions are not followed exactly, including timeouts.
Introduction to configuring Ethernet network and gun movers, requiring Level 4 user access.
List of topics covered in Section 4 regarding Ethernet and Gun Mover Configuration.
Configuration tasks for positioners, reciprocators, and scanners require Level 4 user access.
Using the System Configuration screen to set up Ethernet network and gun mover components.
Configuring the Ethernet network and monitoring its status and nodes.
Using Network Status screen to check Ethernet and CAN network status and access node/host config.
Accessing the Host Configuration screen from the Network Status screen.
Setting up IP addresses for the iControl console in the Remote I/O Network.
Configuring network nodes (positioners, reciprocators, scanners) with MAC, IP, and machine type.
Procedures for iControl versions below 3.0 and version 3 and above regarding node power cycling.
Accessing the Positioner Configuration screen to control gun movement.
Detailed settings for configuring positioners, including orientation, modes, and limits.
Managing positioner operating modes (Auto, Manual, Off) and lockouts.
Setting encoder resolution for positioners based on drive type.
Establishing zero and home positions for positioners, crucial for Auto mode operation.
Standard settings for positioners like orientation and gun separation.
Setting the distance from conveyor centerline to gun tips.
Configuring park/clean and retract positions for positioner movement.
Specific settings for Lance, USA ColorMax, Vertical Positioner, No Drive, and Clean Only options.
Instructions for positioning guns on horizontal positioners and calculating Gun to Conveyor Centerline.
Configuring default and minimum move settings, including lead and lag parameters.
How lead and lag settings overlap and precedence is determined for collision avoidance.
Example of positioner movement when the part is at the lead distance.
Example of positioner maintaining gun-to-part distance as the part moves.
Example of positioner movement when the part is at the lag distance.
Example of lancing default moves for positioners in specific applications.
Overview of reciprocator configuration settings, including modes and limits.
List of settings for reciprocators, including modes, limits, speed, and pattern width.
Managing reciprocator operating modes (Auto, Manual, Off) and lockouts.
Service settings like encoder resolution, max speed, and turn-around offset set by Nordson representative.
Setting acceleration and deceleration time for the reciprocator motor.
Calculating and setting the turn-around offset to compensate for reciprocator overtravel.
Settings for reciprocator side of booth, soft limits to prevent switch tripping.
Configuring hysteresis, park/clean position, fan pattern width, and number of laps.
Selecting reciprocator operation modes: Fixed/Variable, synchronized/unsynchronized, Oscillator.
Setting reciprocator speed based on conveyor speed, stroke length, and pattern width.
Reciprocator stroke length controlled by turn-around points in fixed mode.
Setting top and bottom turn-around limits measured from Reciprocator Home.
Using oscillator mode with fixed mode for stroke length control.
How reciprocator stroke length varies with part dimensions in variable modes.
Setting overtravel limits in variable modes to control spray pattern extension or restriction.
Understanding positive, negative, and zero overtravel settings for reciprocator turnaround.
Adjusting powder pump and atomizing air flow based on stroke length.
Notes on percent adjust being additive and its application to different settings.
Configuring analog scanners for part measurement and enabling them.
Steps to enable analog scanners and select the number of horizontal scanners.
Configuring dual scanners for in/out positioners to measure part width.
Configuring vertical scanners to measure part height for reciprocators or up/down positioners.
Scanner beam resolution and zero offset override information.
Calculating and setting the vertical offset for reciprocators to align guns with scanner data.
Using zero offset override to tune out electrical noise and phantom signals.
Using offset values to eliminate noise and phantom signals in noisy environments.
Explanation of spray gun presets as recipes for specific parts, and system operation in Automatic Part ID mode.
Warning to allow only qualified personnel to perform preset tasks.
Using Gun Control screens to set presets for one gun at a time.
Using the Preset Table screen to view and set presets for all guns in a table format.
Details on the Spray Gun Control screen for individual gun settings.
How to use the Preset Table screen to view and set presets for all guns.
How to select a preset number using up/down arrows or the preset number field.
Touching the Preset Name field to open the keyboard and type a name for the preset.
How flow-rate air and atomizing air control powder output and spray pattern.
Steps for setting air flows using the flow button and slider bar or rotary dial.
Conversion table for 6-mm tubing/100 Plus Nozzle, showing m³/hr vs. P1 bar.
Conversion table for 8-mm tubing/100 Plus Nozzle, showing m³/hr vs. P1 bar.
Configuring Smart Flow mode for venturi pumps, excluding Tribomatic and Prodigy/Encore HD.
How to read smart flow tables for equivalent atomizing and flow-rate air.
Smart flow settings table presented in metric units for powder velocity and air flow.
Ranges for powder velocity (Low, Soft, Medium, Firm, High) and air flow settings.
Smart flow settings table presented in English units for powder velocity and air flow.
Ranges for powder velocity in SCFM and air flow in PSI for smart flow settings.
Air flow settings specific to Prodigy/Encore HD guns, including powder flow and pattern air.
How Fast Pump Mode increases HDLV pump cycle rate for better flow control.
Configuring electrostatic settings like kV, AFC, and Select Charge Mode for spray guns.
AFC setting for Tribomatic guns used to set current feedback alarm level.
How the kV setting determines voltage output and affects electrostatic charge.
Setting AFC for current output and selecting electrostatic charge modes.
Distance from guns to leading edge; positive, negative, or zero values.
Distance from guns to trailing edge; positive, negative, or zero values.
Example illustrating perfect pickoff (Lead=0, Lag=0) for precise spray start/stop.
Example illustrating extended spray (Lead=5, Lag=5) to wrap powder around part edges.
Example illustrating restricted spray (Lead=-5, Lag=-5) to prevent powder wrap.
Example illustrating extended-restricted spray (Lead=5, Lag=-5) for specific part end coverage.
Assigning spray guns to zones for triggering when a part is detected.
Setting zone assignment to zero for a preset to prevent a spray gun from triggering.
Copying flow and electrostatic settings from one preset to others for all guns.
Copying selected preset settings from Gun 1 to presets for all other guns.
Selecting and copying specific preset settings between guns and presets.
Steps to select source settings, ranges, and destination for copying.
Explanation of positioner presets as part-specific move settings and their relation to default settings.
Positioner presets contain move settings for specific parts, up to 255 unique presets.
Steps for setting up positioner presets, including lead/lag distances and positioning modes.
How to view default settings for a positioner using the Positioner Selector.
Copying selected preset settings from positioner 1 to the rest of the positioners.
Saving preset settings to the database and resetting selected presets to defaults.
Referencing Positioner Configuration for minimum/default settings and examples.
Example illustrating fixed positioning moves based on part ID and distance.
Setting up variable positioning for contouring, defining gun-to-part distance.
Example of variable positioning for contouring, maintaining gun-to-part distance as part width changes.
Setting up variable positioning for lancing and contouring, including retraction.
Example of variable positioning for lancing and contouring, including retraction to wait for the next part.
Setting up variable positioning for lancing into deep recesses, using default and preset settings.
Example of variable positioning for deep recesses, moving guns in and out.
Explanation of reciprocator presets as part-specific settings and their relation to default configurations.
Overview of reciprocator settings including trigger points, turn-around points, speed, and air adjust.
How to set up a preset for a reciprocator using the Preset Selector.
Copying, saving, and resetting reciprocator presets using the screen buttons.
Configuring fixed mode settings for reciprocators, including gun on/off points and turn-around limits.
How reciprocator speed is controlled in Fixed modes, synchronized or not.
Configuring variable mode settings for reciprocators, including overtravel and turn-around limits.
Understanding positive and negative overtravel settings for spray pattern control.
Adjusting spray gun flow-rate and atomizing air settings by percentage for reciprocators.
How percent-adjust settings work in Variable and Fixed modes for reciprocators.
Guide to operating the iControl system, covering screen functions, controls, and modes.
Explanation of screen icons used in operation and the system startup procedure.
Reference guide to icons for settings like flow-rate, atomizing air, voltage, and lead/lag.
Icons representing trigger modes: Automatic, Manual, Off, and Trigger Switch.
Steps for turning on the console and loading the iControl software.
Explanation of keyswitch positions: Ready, Lockout, and Conveyor Bypass.
Overview of the main screen interface, buttons, and their functions.
Details on buttons for alarms, presets, configuration, gun controls, and positioner/reciprocator controls.
Controlling global operating modes for guns, positioners, reciprocators.
Using Global Control for manual spray, selecting presets and triggering guns.
Accessing the Part ID Control screen to view current Part ID mode.
Managing Part ID modes (Auto/Manual) and performing batch coating operations.
Manual purge controls for Versa-Spray guns requiring installed purge kits.
Purge controls for Prodigy/Encore HD guns, configured via a separate screen.
Explanation of percent adjust functions for adjusting spray flow and fan pattern.
How percent adjust functions are additive and combine for a final adjustment factor.
How conveyor speed percent adjust works to modify spray flow based on speed.
Screen elements for adjusting flow-rate, atomizing air, speed, and dead band.
Using Gun Control screens to adjust presets and control individual guns.
Changing gun trigger mode (Auto, Manual, Off) and manual triggering.
Shutting down individual guns by changing their mode to Manual or Off.
Returning all guns to operation by setting Global Operation Mode to Auto.
Accessing Positioner Control screens to individually control positioners.
Managing positioner operating modes and locks, including warnings.
Why positioners must be homed after power cycling or selecting Auto mode.
The sequence of movements positioners make during startup and part tracking.
Accessing Reciprocator Control screens to manage reciprocator operation.
Managing reciprocator operating modes and locks, including warnings.
How the Default Settings or Preset Settings button appears based on part data.
Adjusting reciprocator settings based on mode (Fixed or Variable) for desired movement.
Using the lap calculator to experiment with reciprocator settings and visualize results.
Explaining how to use settings and view results in the lap calculator.
Guide to monitoring system status, including guns, alarms, and network.
Monitoring the status and operation of individual spray guns.
Monitoring gun status via buttons, including trigger mode and color indicators.
How the Global Status screen displays preset number, air flow, and electrostatic output.
How to open the Global Hourmeter screen from the Global Status screen.
Tracking operating hours for pumps and guns, and maintenance timers.
Viewing status indicators on the Gun Control screen for a specific gun.
Accessing the hourmeter screen for a gun to view operating hours.
Display of Part ID number and name at the bottom left of the main screen.
Using the Input Status screen to check zone photoeyes, scanners, and Part ID inputs.
Monitoring the progress of color change operations in different booth types.
Using the Park Indicator and Button to monitor and abort color change operations.
How fault codes appear on gun control and alarm screens for gun-related issues.
Accessing the Alarm screen and resetting active faults using Reset All or Reset Selected buttons.
Resetting a selected fault and the consequence if the problem is not corrected.
Accessing the Alarm Log to view fault, reset, and status messages.
How to open the Network Status screen via System Configuration.
Interpreting node status buttons (Green/Red) for Ethernet communication.
Display of node status counters and codes for troubleshooting.
Reference for understanding node status codes and layout codes for system diagnostics.
Classification of node errors: Ethernet connections, programming, noise, hardware.
List of common node error codes (65-164) and their descriptions.
Four types of CAN network errors: Bit, Stuff, Form, and Other errors.
Explanation of "Ack slot OEA" error and interpretation of transmit/receive errors.
Guidance on copying record sheets to document system configuration and preset settings.
Recommendation to back up the user data card immediately after configuration.
Template for recording settings for guns, zone inputs, and Part ID.
Recording settings for horizontal and vertical analog scanners.
Record sheet for standard gun purge settings, including evacuation and soft start.
Record sheet for Prodigy gun purge settings and bank assignments.
Record sheet for gun pickoff distances and purge bank numbers for each gun.
Columns include Console, Gun Number, Pickoff, and Purge Bank No.
Record sheet for Remote I/O and LAN network settings, and node configuration.
Table for recording Device, MAC, TCP/IP, and Machine Type for network nodes.
Record sheet for positioner configuration settings, including encoder resolution and move parameters.
Recording settings for each positioner (GP 1-4) like side of booth, gun centerline, and lance option.
Record sheet for reciprocator configuration settings, including fixed and variable modes.
Recording mode settings (Fixed/Variable) and default fixed/variable settings.
Record sheet for reciprocator percent adjust settings for air flow based on stroke length.
Recording percent adjust values for Flow-Rate and Atomizing air for different stroke lengths.
Record sheet for spray gun preset settings, including flow, kV, AFC, lead, lag, and zone.
Columns for Gun, Flow-Rate Air, Atomizing Air, kV, AFC, Select Charge Mode, Lead, Lag, Zone.
Record sheets for positioner preset settings, including lead, lag, and position values.
Recording lead, lag, fixed/variable mode, variable position, and fixed position for each positioner.
Record sheets for reciprocator preset settings, including fixed, variable, and percent adjust values.
Recording fixed settings, variable settings, and percent adjust values for each reciprocator.
