Inocontroller Control Module Instructions Manual Sames DRT7134 Uk

Inocontroller
Control module
Instruction manual
DRT7134
C - 2022/12
DRT7134
C - 2022/12
All communication or reproduction of this document, in any form whatsoever and all use or communication of its
contents are forbidden without express written authorisation from Sames.
The descriptions and characteristics mentioned in this document are subject to change without prior notice
© Sames 2020 - translation of the original version
Sames operating manuals are written in French and translated into English, German, Spanish, Italian and Portuguese.
The French version is deemed the official text and Sames will not be liable for the translations into other languages.
2 Member of Exel group

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Services
Certification and referencing
Sames is certified as a training center by the DIRRECTE of the Auvergne Rhône Alpes region under the number 84
38 06768 38.
Our company provides, throughout the year, training courses allowing you to acquire the essential know-how for the
implementation and maintenance of your equipment in order to guarantee its performance in the long term.
A catalog is available on request.
www.sames.com/france/fr/services-training.html
Line audits
As part of a technical assistance program for our customers using Sames equipment, the line audits are intended to
help you optimize and control your production tool.
Our network of experts is continuously trained and qualified to provide our customers with technical expertise on the
liquid or powder installations in which our equipment is integrated. The global environment of the production lines is
taken into account during this technical audit.
A brochure is available for download:
www.sames.com/france/fr/services-service-contract.html
Maintenance program
An annual maintenance program (including or not the consumables to be replaced during each intervention) can be
considered with the partnership of Sames. It is associated with a preventive maintenance plan established during a
first audit visit which details the control points necessary to guarantee the performance of the installed equipment.
Hotline

Inocontroller
Control module
1. Health and safety instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.1. Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2. Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3. Meaning of pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4. Precautions for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5. Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2. Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
3. Characteristics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
3.1. Mechanical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2. Electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3. Air compressed quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4. Operating principle of the Inocontroller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
4.1. Pneumatical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2. Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3. State of the Inocontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.4. Configuration of the communication network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4.1. Network address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4.2. Network speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.5. Bootloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.6. Inhibition of injection air flow monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5. Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
5.1. Connector A: +24 V DC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2. Connector B - I/O (Input/Output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.3. Low voltage connector to Inogun A projector or Inogun M spray gun . . . . . . . . . . 18
5.4. Communication network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6. Cabling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
6.1. Connector A: + 24 V DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2. Connector B - I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7. High voltage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21
7.1. Characteristics of projector output voltage and current . . . . . . . . . . . . . . . . . . . . . . . . 21
8. Fault management- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
8.1. Fault list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.2. Actions following a fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9. Communication with PLC with optional module - - - - - - - - - - - - - - - - - - - - - - - - 24
9.1. Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.1.1. Ethernet IP Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.1.2. Profinet Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.1.3. CC-Link module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.1.4. Profibus Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

9.1.5. EtherCat Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9.2. Data exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.2.1. Exchanging data flags for CC-Link only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.2.2. From PLC to the Inocontroller module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.2.3. From Inocontroller to PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10. CAN Communication with PLC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
10.1. Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10.2. Data exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.2.1. From CAN to the Inocontroller module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.2.2. From Inocontroller to a CAN module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
11. Spare parts list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41
12. Revision index History - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43

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1. Health and safety instructions

1.1. Applicable standards
Inocontroller control module has been designed according to standards indicated below:
Canadian Standards:
• CSA C22.2 No. 61010-1:12
• CSA C22.2 No. 213:19
• CSA C22.2 No. 0:20
• CSA C22.2 No. 60079-31:15 as a guide
• EN 50177:09 / A1:13 as a guide
• EN 50500-2:18 as a guide
US Standards:
• FANSI/ISA-61010-1: 3rd Ed.
• FM3600: 2018
• FM3611: 2018
• FM 7260: 2018 as a guide
• UL60079-31:2nd Ed. as a guide
Installation:
• In Canada, the installation has to be in compliance with the Canadian Electrical Code C22.1 part I, standard
safety for electrical installations.
• In the USA, the installation has to be in compliance with the National Electrical Code NFPA 70.
1.2. Marking
This marking indicates that this control module is an item of equipment that must be installed outside of an
EXplosive ATmosphere and that it contributes to the safe operation of the equipment Inogun A or Inogun M
installed in an Explosive Atmosphere that is connected to it. The operating procedure for the equipment is
described in the user manual of the projector or of the spray gun.
The X sign placed after the EU type examination certificate number indicates that this equipment is subject to a
special condition of use with regard to the ambient operating temperature, which must be between 0°C and 40°C.

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1.3. Meaning of pictograms
Warning Warning Warning Warning General warning

electricity Automatic start-up Hot surface Explosive material sign
Warning Warning Warning for Warning Warning

High pressure Crushing of hands explosive Flammable Corrosive
atmospheres material subtance
Warning Warning No access for Wear ear Wear a face

Toxic material Harmful products people with active protection shield
implanted cardiac
devices
Wear respiratory Wear safety Wear protective Wear protective Wear head
protection footwear clothing gloves protection
Opaque eye General mandatory Connect an Refer to

protection must action sign earth terminal Instruction manual
be worn to the ground

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1.4. Precautions for Use

This document contains information that all operators should be aware of and understand before using the
Inocontroller control module. This information highlights situations that could result in serious damage and indicates
the precautions that should be taken to avoid them.
Before any use of the Inobox control module, check that all operators:
• have previously be trained by the company Sames, or by their distributors registered by them for this
purpose.
• have read and understood the user manual and all rules for installation and operation, as laid out
below.
It is the responsibility of the operators’ workshop manager to ensure these two points and it
is also his responsibility to make sure that all operators have read and understood the user
manuals for any peripheral electrical equipment present in the powdering area.
1.5. Warnings
This equipment can be dangerous if not used in compliance with the safety regulations.
It is the customer’s responsibility to verify which local fire and safety standards are applicable
for use of the Inocontroller.
The control module Inocontroller must not be installed in an explosive atmosphere.
It is imperative that anyone wearing a pacemaker does not use the equipment and does not
enter the projection area.
High voltage can cause the pacemaker to malfunction.
Equipment performance is only guaranteed if original spare parts distributed by Sames

are used.
To guarantee an optimal assembly, spare parts must be stored in a temperature close to their
temperature of use. Should the opposite occur, a sufficient waiting time must be observed
before the installation, so that all the elements are assembled in the same temperature.

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This equipment may be hazardous if it is not used, disassembled and reassembled in

accordance with the rules indicated in this manual and in any applicable European Standard or
national safety regulations.
• The control module is intended to be installed in category II (according to EN 61010-1) inside an electrical
cabinet manufactured by Sames, which guarantees a basic level of product sealing relative to its environment
(e.g. water spraying, dust pollution).
All other cases of use are to remain under the user’s liability (i.e. outside of the electrical cabinet or reliance on
a cabinet not manufactured by Sames).
• The Inocontroller control module must not be installed outdoors.
• The ambient temperature around the Inocontroller module must be no greater than 40°C.
• The Inocontroller module must not be altered from its original condition.
• Only Sames spare parts, or a repair performed by the Sames repair department, are able to ensure and
guarantee the operational safety of the Inocontroller module.
• Turn off the electrical power supply to the Inocontroller module before disconnecting the connectors from
the module.
• Any repairs on the Inocontroller module with the power supply still on can only be performed by personnel
certified and trained for electrical repairs.
An inviolability label is located on the side of the Inocontroller. Any damage to or absence of
this label will result in the loss of the Sames manufacturer's guarantee.

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2. Description
The Inocontroller is a control module for controlling the automatic Inogun A projector or the manual Inogun M
spray gun. The Inogun A projector or the Inogun M spray gun have the function of projecting the electrically charged
powder by means of a high voltage unit integrated into the barrel and delivering up to 100kV and 110 μA.
The Inocontroller manages, by microcontroller, the control of the high voltage unit and 3 proportional solenoid
valves. In return, a reading of the voltage and high voltage current is performed, as well as the flow and current of the
3 proportional solenoid valves.
The Inocontroller is controlled by a PLC network or via a CAN link.

The Inocontroller is accessible for Sames maintenance via USB connection.
For instance:
Synoptic of an installation with an Inogun A projector
PLC + 24VDC LPS
Network Communication Air supply Powder supply Inogun A

Module

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Front Face:
16
3
15
14 4
5
13
6
12
11
10
9 8
Item Description
1 Fixing points
2 J: Wireless network antenna (optional)
3 C: not connected pneumatic output
4 Blowing electrode pneumatic output
5 Dilution pneumatic output
6 Injection pneumatic output
7 Main pneumatic supply
8 G: plug for powder projector connector
9 Ground connection terminal
10 K: network communication module location
11 E: micro USB type B port for maintenance
12 LED status
13 S1 and S2: micro switches for address, speed, communication and Bootloader configuration
14 B: I/O connector (Inputs / Outputs)
15 Location of cable shielding connections ( jumpers supplied)
16 A: + 24VDC power supply connector

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3. Characteristics
3.1. Mechanical characteristics
Dimensions Width 105.2 mm x height 270 mm x depth 208 mm (without connector )

Weight 2840 g
Protection index IP20 - Degree of pollution: 2 (1)
Box material Galvanised steel
Ground shield M6 brass pin
Fastening mode M5 x 8 (qty 4)
(1): Level 2: Pollution either non-conducting or occasionally and temporarily conducting caused by condensation.
105,2 mm
61,2 mm
Ambient temperature during operations 0° C min. -> 40°C max.

Maximum storage / transport temperature 70°C max.
Maximum relative humidity 93% (4 hours)
Maximum altitude 2000 m
The Inocontroller module, the box in which it is mounted must be correctly connected to
the installation ground by a cable or metal braid with a cross section greater than or
equal to 6 mm2.
Electrical earth contacts must be free of paint or any form of more or less insulating surface.

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3.2. Electrical characteristics
Using voltage: VLSV (2) 24 VDC (min. 21.6 VDC - max. 26.4 VDC)
Maximum Input Power (3) 40 W @ 24V DC
Maximum current (3) 1,7 A @ 24V DC
Self-resettable, non-removable 3 A fuse
Protection circuit Protective diode against polarity inversion 24V DC
Internal limitation 30V
Max. output voltage (to projector) 42 V rms
Max. output current (to projector) 400 mA rms
Maximum frequency (to projector) 22,5 kHz +/-20% (min. 17 kHz / max. 27 kHz)
Maximum pressure supply 7 bar +/-1bar
(2): Very Low Safety Voltage: A +24 VDC LPS (Limited Power Source) supply is recommended to supply the
Inocontroller module.
(3): The maximum power value is given all active functions simutaneously. (HV and Air).
Maximum current: Inocontroller module alone : 1.7A / Network communication module: 0,5A max (between 250mA
and 0.5A depending on the type of network used). The Inocontroller control module is design to support a network
of 0.5A .
3.3. Air compressed quality

Characteristics of compressed air supply according to the standard NF ISO 8573-1:
Maximum dew point at 6 bar (87 psi) Class 4 i.e + 3°C (37°F)
Maximum particle-size of solid pollutants Class 3 i.e 5 μm
Maximum oil concentration Class 1 i.e 0,01 mg/m03*
Maximum concentration of solid pollutants Class 3 i.e 5 mg/m03*
*: Values are given for a temperature of 20 °C (68 °F) at an atmospheric pressure of 1 013 mbar.
Non-compliance with these characteristics may result in incorrect operation of

the“Inocontroller” control module.

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4. Operating principle of the Inocontroller

4.1. Pneumatical
The Inocontroller control module manages the powdering air (injection, dilution and electrode blowing) that supplies
powder to the Inogun A projector or to the Inogun M spray gun.
Item Icons Description Characteristics

1 C - (not connected) -
2 Blowing air Hose Dia.: 4/6 rilsan
3 Dilution air Hose Dia.: 4/6 rilsan
4 Injection air Hose Dia.: 6/8 rilsan
5 Air supply Hose Dia.: 8/10 rilsan

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4.2. Startup
• Connect peripheral equipment (PLC, projector or spray gun, powder pump, etc.).
• Connect the air and powder supplies.
• Connect the +24V DC to the Inocontroller module.
The Inocontroller module is then ready to start.
The Inocontroller module is controlled by the PLC.
Remarks:
If the projector is not connected when the module is switched on, a " 37 - Spray gun or projector connector fault" is
immediately triggered.
If the connected PLC does not request the control when the module is switched on, a "17 - Absence of control mode
fault" is triggered after few seconds. As soon as the PLC requests the control, the fault will be immediately
automatically reseted.
High voltage control and spraying:

The high voltage and spraying control can be done by the PLC connection or by a wired connection.
When using a wired control, for HV and spraying, the PLC must not request the high voltage control. (CAN control bit
2 to zero, see § 10.2.1 page 38).
This solution allows to save time in transmitting the work request.
The high voltage and spray settings must be set beforehand via the PLC.
When an Inogun M spray gun is connected, the HV trigger is controlled by the operator at the spray gun level, if the
PLC authorizes it.
The operator can also modify the injection set-point using the spray gun keys, if the PLC does not prohibit it.
4.3. State of the Inocontroller

The state of the Inocontroller is displayed on the front panel by a series of three indicator lights (LEDs).
Symbol Indicator Status Indication

Off Absence +24 V power supply
Green
On Presence +24 V power supply
Off No High voltage at projector output
On High voltage at projector output
Yellow
Blinking Active Bootloader mode
On Fault present
Red
Blinking Connected communication module not recognized

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4.4. Configuration of the communication network

The Inocontroller has two microswitches S1 and S2 on its front panel to configure network addressing and network
communication speed.
S1: Configuration S2: Speed
The microswitches must be properly configured before the module is powered up.
4.4.1. Network address

Micro-switches S1, from 1 à 8 allow the address configuration by binary code on 8 bits or 255 positions.
#1 #2 #3 #4 #5 #6 #7 #8
S1 OFF 0 0 0 0 0 0 0 0
ON 1 2 4 8 16 32 64 128
The least significant bit corresponds to micro-switch N°1.
Example : we want to configure the module at address 147, binary code: 10010011
Position of the micro-switches:
#1 #2 #3 #4 #5 #6 #7 #8
S1
ON ON OFF OFF ON OFF OFF ON

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4.4.2. Network speed

Micro-switches S2, from 1 à 4 allow the speed communication configuration by binary code on 4 bits or 16 positions.
3 microswitches 5 to 7 are in spare, the microswitch 8 is used for the Bootloader.
#1 #2 #3 #4
S2 OFF 0 0 0 0
ON 1 2 4 8
The least significant bit corresponds to micro-switch N°1.
4.5. Bootloader
Micro-switch S2#8 allows reprogramming the Inocontroller module via USB port.
This action can only be carried out by personnel trained by Sames.
Reprogramming is possible if the micro-switch S2#8 is ON (Boot Active)at startup and the yellow LED is flashing to
indicate that the boot is active.
In that situation, no function of the Inocontroller module is active.
if the micro-switch S2#8 is OFF (Boot inactive), the Inocontroller module is active.
4.6. Inhibition of injection air flow monitoring
Micro-switch S2#7 is used to disable the monitoring of the

injection air flow.
If the micro-switch is in the OFF position, monitoring is active

(factory setting).

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5. Connections
5.1. Connector A: +24 V DC power supply
Pin Description Designation Characteristics

1 + 24 VDC + 24 VDC / 2A 1 2
Wire Terminal l
0V common to 26-13AWG / 0,2-
2 0 VDC the module and
2,5 mm2
ground terminal
5.2. Connector B - I/O (Input/Output)
Pin Designation Description Characteristics

1 0 V TRIGGER 0V dry contact pilot for ON / OFF high voltage
Cathode input of the pilot optocoupler On /
2 TRIGGER COM
Off high voltage Wire Terminal
3 0 V CLEANING 0V for dry control contact On / Off cleaning 26-16 AWG / 0,2 -1,5 mm2
Cathode input of the pilot optocoupler On /
4 CLEANING COM
Off cleaning
Output of the NO dry contact (normally open) Wire Terminal
5 N.O FAULT RELAY
of the fault relay 26-16 AWG / 0,2 -1,5 mm2
Relay dry contact
Output of the NC contact (normally closed) of 6 A /250 V AC max
6 N.C FAULT RELAY
the fault relay Max. switching capacity:
1500VA
Wire Terminal
7 0V 0V
26-16 AWG / 0,2 -1,5 mm2
8 CAN H Data bus CAN signal H
Wire Terminal
9 CAN L Data bus CAN signal L
26-16 AWG / 0,2 -1,5 mm2
10 0V 0V
5.3. Low voltage connector to Inogun A projector or Inogun M spray gun

The high voltage unit of the projector or the spray gun is connected by a low voltage cable to the module
Inocontroller. This cable is connected to the module via a circular connector.

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5.4. Communication network

The Inocontroller is designed to be controlled by a communication network
To do this, it is necessary to install a communication module in the intended location (K) (see § 2 page 10).
Module installation:
• Remove the protective cover.
• Insert the module in its housing by pressing lightly down.
• Using a # 8 Torx screwdriver, lock the module by tightening

the two screws to a torque of 0.25 N.m.
Uninstall:
• Using a # 8 Torx screwdriver, unlock the module by loosening

the two screws
• Remove the module.

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6. Cabling
6.1. Connector A: + 24 V DC
Function to be wired outside the module
Designation Pin
+ 24 VDC 1 24 V DC
0 VDC 2 0V
6.2. Connector B - I/O

Function to be wired outside the module
Designation Pin
0 V TRIGGER 1
On / Off powdering trigger
COM TRIGGER 2
0 V CLEANING 3
On / Off cleaning
COM CLEANING 4
N.O FAULT 5
N.C FAULT 6 Fault

(Closed = present fault)
DEFAUT COMMUN 7
CAN H 8
Communication CAN
CAN L 9
0V 10

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7. High voltage
7.1. Characteristics of projector output voltage and current
The Inocontroller module has a voltage and current mapping control that limits the operation according to curve 1.
Operator can set all the voltage / current value pairs that are including in this 100kV/110μA characteristic envelope.
For each UHT IR output current point corresponds to a maximum output voltage point, UR according to a mapping
recorded in the HVU and not modifiable by the user.
)
UR (
IR ( )
Curve 1
Example 1: 70kV / 30μA. The operating point is inside the curve, the voltage (70kV) and current (30μA) can be
supplied if the system requires it.
Example 2: 70kV / 80μA. The operating point is outside the curve, current will be limited to 55μA. If electrical charge
requires more current, voltage will be limited following the curve.

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8. Fault management
There are two types of faults:
• Resettable faults by fault acknowledgment.
• Blocking faults that require a restart of the +24V DC supply of the Inocontroller module.
Whatever the type of fault triggered, the Inocontroller switches off the high voltage and powdering.
Fault relay and red LED (fixed light) are activated.
For a “network communication fault“, the red LED is flashing
8.1. Fault list
Fault Fault information

Communication module fault The communication module plugged into slot K is not recognized or not
Only indicated by flashing red LED allowed. This fault requires a power-up to be acknowledged.
1 - Program fault Microcontroller module fault. This fault requires a power-on to be reseted.
The 24V power supply voltage has exceeded the authorized operating limits:
2 - + 24 V power supply fault
21 V < U < 28 V. This fault requires a power-on to be reseted.
Voltage present on the bus without HV request. The fault requires a power-
up to be acknowledged.
5 - Voltage coherence fault
HV request without voltage present on the bus. The fault can be reset by
acknowledgment of the fault after 10 s of waiting.
Communication is lost while the API is in control mode. The fault can be reset
by acknowledgment of the fault The communication module is detected but
17 - Absence of control mode fault
the control is not activated. It is just necessary to activate the control of this
module to acknowledge the fault.
The output power of the module or the inverter current has been exceeded.
21 - Bus power fault
Resettable by Fault Acknowledgment.
The maximum high voltage current or the supply current of the barrel has
22 - Safe shutdown fault
been exceeded. Resettable by acknowledgment of fault.
The external high voltage/powdering control trigger is controlled when the
24 - Trigger request at startup
module is powered on. Resettable by Fault Acknowledgment
Maximum temperature overflow of the internal power supply of the module.
28 - Temperature fault
Resettable by Fault Acknowledgment
The barrel is not or badly connected to the module.
29 - HVU link fault
Resettable by Acknowledging Fault
Internal bus overvoltage (detected by hardware or software)
30 - Internal BUS fault
Resettable by fault acknowledgment
An injection control is activated without pressure feedback. Resettable by
32 - Injection fault Fault Acknowledgment.
See the position of micro switch S2#7 (see § 4.6 page 17).
A dilution control is activated without pressure feedback. Resettable by Fault
33 - Dilution fault
Acknowledgment
A blowing control is activated without feedback from the activated valve.
34 - Blowing fault
Resettable by Fault Acknowledgment
No projector or spray gun connected
37- Spray gun or projector connector fault Resettable by Acknowledgment Fault, unless the connected projector or
spray gun is different from that at start-up

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8.2. Actions following a fault
Fault Action to be performed

Communication module fault Check the P/N of the module used for network communication, it must match
Only indicated by flashing red LED a Sames number. Replace the network communication module
1 - Program fault The microcontroller is faulty. If the problem persists, contact Sames.
Control power supply input on the module. It must be 24 V DC (min. 21,6 V
2 - +24V power supply
DC / max. 26,4 V DC).
Check the operation by changing the HVU.
5 - Voltage coherence fault
If the problem persists, contact Sames.
The CAN Communication is lost while the PLC is in control mode.
17 - Absence of control mode fault
The fault can be reset by acknowledgment of the fault
The module delivers too much power or current at the output to the HVU.
Check the connection between the module and the sprayer (G connector on
21 - Bus power fault
the module). Check the internal connection of the sprayer and the condition
of the HVU. None of these components must be damaged.
The module delivers too much current at the output to the HVU.
22 - Safe shutdown fault Check the connection between the module and the sprayer (G connector on
the module) Check the internal connection of the sprayer and the condition
of the HVU.
Check that the external trigger connection (connector B) is not activated, or
the terminals are short-circuited.
24 - Trigger request at startup
In the case of the manual spray gun, check that the trigger is not activated at
power up
Check the ambient temperature as close as possible to the module. This
28 - Temperature fault
temperature must not exceed 40 ° C.
Check the connection between the module and the sprayer (G connector on
29 - HVU link fault the module) Check the internal connection of the sprayer and the condition
of the HVU.
The maximum level of the internal supply voltage to the module has been
30 - Internal BUS fault
exceeded. If the problem persists, contact Sames.
Check the air hose connections.
32 - Injection fault Check the air pressure and flow rate at the module inlet and outlet.
The injection fault can be disabled (see § 4.6 page 17)
Internal electrode blowing valve is not correct, if the problem persists contact
34 - Blowing fault
Sames.
37- Spray gun or projector connector fault Check the circular connector G on the back of the module

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9. Communication with PLC with optional module

In the network mode, a PLC manages the data display and / or the data control of the Inocontroller module.
It communicates with the module using the communication network module added on the K location on the
Inocontroller module.This communication module specific to Sames exists in different protocols : Ethernet IP,
Profinet, Ethercat,CClink, Profibus.
The network cable must be shielded and it is recommended to connect its shield closer to the connectors of the
Inocontroller module.
9.1. Characteristics
9.1.1. Ethernet IP Module

9.1.1.1. Front view of the RJ45 module

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9.1.1.2. Ethernet IP LED
‘Network Status’ Led (1) Description

Off No power or no IP address
Green Online, one or more connections established (CIP Class 1 or 3)
Green, flashing Online, no connection established
Red Duplicate IP address, FATAL error
Red, flashing One or more connections timed out (CIP Class 1 or 3)
‘Module Status’ Led (2) Description

Off No power
Green Controlled by a scanner in Run state
Green, flashing Not configured, or Scanner in idle state
Red Major fault
Recoverable fault(s). Module is configured, but stored parameters differ
Red, flashing
from currently used parameters.
LINK Activity Leds (3) and (4) Description

Off No link, no activity
Green Link (100 Mbit/s) established
Green, flashing Activity (100 Mbit/s)
Red Link (10 Mbit/s) established
Red, flashing Activity (10 Mbits/s)
9.1.1.3. Ethernet IP setting

For Ethernet IP, it is necessary to fix an IP address and a subnet mask.
The IP address should be in the same range as the IP address for the PLC system.
For Ethernet IP, the characteristics of a device are stored in an ASCII data file with the suffix EDS.
This file is used by the PLC configuration tools when setting up the network configuration
(with Instance ID for PLC Input =100, and instance ID for PLC output =150).
This configuration file can be downloaded from www.sames.com.
DHCP mode
The module supports the DHCP mode, which may be used to retrieve the IP settings from a DHCP-server
automatically.
In this case all micro-switches of S1 must be in the ON position (value 255) and at least one of the first four
microswitches of S2 (1 to 4) must be set to ON to activate this mode.
Addressing mode by micro-switches

At least one of the first four microswitches of S2 (1 to 4) must be set to ON to activate this mode.
By fault the IP address is 192.168.0.xxx where xxx is defined by S1 micro-switches and the SubNet mask is
255.255.255.0.
For example to fix IP4 to value 23, the micro-switches 1, 2, 3 and 5 of S1 must be put to the ON state and the others
one to the OFF state.
Configuration mode via the RJ45 configuration utility

It is possible to change the entire IP address and subnet mask using a configuration utility such as IPConfig and
connecting directly to the IP Ethernet module via an RJ45 cable.
In this case all micro-switches S1 and S2 must be put to OFF state.

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9.1.2. Profinet Module

9.1.2.1. Front view of the RJ45 module
9.1.2.2. Profinet LED
Led Network Status Description Comments

No power
OFF Offline
No connection with IO Controller
Connection with IO Controller established
Green On line (RUN)
IO Controller in RUN state
Connection with IO Controller established
Green, 1 flash On line (RUN)
IO controller in STOP state or IO data bad
Green, blinking Blink Used by engineering tool to identify the node on the network
Red FATAL event Major internal error (combined with a red Module Status Led)
Red, 1 flash Station name error Station Name not set
Red, 2 flashes IP adress error IP address not set
Red, 3 flashes Configuration error Expected identification differs from Real Identification
Module Status Led Description Comments

OFF Not initialized No power or Module in SETUP or NW_INIT state
Green Normal operation Module has shifted from the NW_INIT state
Green, 1 flash Diagnostic event Diagnostic event present
Exception error or Device in EXCEPTION STATE or
Red
Fatal event Major internal fault (combined with a red network Status Led)
Alternating Do NOT power off the module. Turning the module off during this
Firmware update
Red / Green phase could cause permanent damage
Link activity Led (3) and (4) Description Comments

OFF No link, no activity No link, no communication present
Green Link Link established, no communication present
Green, flickering Activity Link established, communication present

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9.1.2.3. Profinet Settings

The module needs to be assigned a Station Name in order to participate on PROFINET.
The Station Name is SK-CMPP-xxx where xxx is defined on 3 digits by S1 micro-switches on the Inocontroller.
For example to fix the Station Name to SK-CMPP-023, the micro-switches 1, 2, 3 and 5 must be put to the ON state
and the others one to the OFF state.
If all micro-switches are OFF, the station name is assigned by the configuration tool.
On PROFINET, the characteristics of a device are stored in an XML data file.

This file, referred to as the “GSD” file, is used by PROFINET engineering tools when setting up the network
configuration. This configuration file can be downloaded from www.sames.com.
9.1.3. CC-Link module

9.1.3.1. Front view CC-Link module
9.1.3.2. CC-Link LED
RUN LED (1) Description

OFF No network participation, timeout status (no power)
Green Participating, normal operation
Red Major fault (FATAL error)
ERROR LED Description

OFF No error detected (no power)
Red Major fault (Exception or FATAL event)
Red, flickering CRC error (Temporary flickering)
Red, flashing Station Number or Baud rate has changed since startup (flashing)
9.1.3.3. CC-Link connector
Pin Signal Comments

1 DA Positive RS485 RxD/TxD
2 DB Negative RS485 RxD/TxD
3 DG Ground signal
4 SLD Cable shield
5 FG Functional Earth

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9.1.3.4. CC-Link settings

On CC-Link, each device on the network must be assigned a unique Station Number.
The highest possible Station Number depends on the number of occupied stations.
Only one stations is occupied by the communication module.
CC-Link Version 2 is used with 2 extension cycles to have larger data size (32 bits and 8 words).
Only words are used for process data, but the last 16 bits of the bits area are used for
exchanging flags (& 9.2.1) in order to start the network.
The Station number is fixed by S1 micro-switches on the Inocontroller module.

For example to fix the Station Number to value 23, the switches 1, 2, 3 and 5 must be put to the ON state and the
others one to the OFF state.
The module supports all common CC-Link baud rates up to 10Mbps.

The baud rate is defined by S2 micro-switches on the Inocontroller module :
• 0 -> 156 kbps (all micro switches are set to OFF)

• 1 -> 625 kbps
• 2 -> 2,5 Mbps
• 3 -> 5 Mbps
• 4 -> 10 Mbps
Each device on CC-Link is associated with a CC-Link Family System Profile (CSP+ file), which holds a description of
the device and its functions.
This configuration file can be downloaded from www.sames.com.

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9.1.4. Profibus Module

9.1.4.1. Front view Profibus module
9.1.4.2. Profibus LED
1 - OPERATION Led Description

OFF Not online / No power
Green Online, data exchange
Flashing green Online, clear
Flashing Red (1 flash) Setting error
Flashing Red (2 flashes) Profibus configuration error
2 - STATUS Led Description Comments

OFF Not initialized Module in SETUP or NW_INIT state
Green Initialized The module has left the NW_INIT state
Flashing Green Initialized, diagnostic event(s) present Extended diagnostic bit is set
Red Exception error Module in exception
9.1.4.3. Profibus connector
Pin Signal Comments

1
2
3 B Line Positive RS485 RxD/TxD
4 RTS Request to send
5 GND Bus Ground (isolated)
6 + 5V Bus Out +5 V terminaison power (isolated, short-circuit protected)
7
8 A Line Negative RS485 RxD/TxD
9
Internally connected to the Anybus protective ground via cable
Cable shield
shield filters according to the Profibus standard

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9.1.4.4. Profibus settings

The module must be assigned a unique Node address (a device address) in order to be able to communicate on the
PROFIBUS network. The valid settings range is from 0... 125.
The Node address is fixed by S1 micro-switches on the Inocontroller module.

For example to fix the Node address to value 23, the switches 1, 2, 3 and 5 must be put to the ON state and the
others one to the OFF state.
The baud rate is detected automatically by the module. The following baud rates are supported: :
9.6 kbps - 19.2 kbps - 45.45 kbps - 93.75 kbps - 187.5 kbps - 500 kbps - 1.5 Mbps - 3 Mbps - 6 Mbps - 12 Mbps.
On PROFIBUS, the characteristics of a device are stored in an ASCII data file with the suffix GSD.
This file is used by the PROFIBUS configuration tool when setting up the network (DP-V1).
Remarks: This configuration file can be downloaded from www.sames.com.
9.1.5. EtherCat Module

9.1.5.1. Front view EtherCat module
9.1.5.2. LED EtherCat
RUN Led Description Comments

OFF INIT EtherCAT device in ‘INIT’-state (or no power)
Green OPERATIONAL EtherCAT device in ‘OPERATIONAL’-state
Green, blinking PRE-OPERATIONAL EtherCAT device in ‘PRE-OPERATIONAL’-state
Green, single flash SAFE-OPERATIONAL EtherCAT device in ‘SAFE-OPERATIONAL’-state
Flickering BOOT The EtherCAT device is in ‘BOOT’ state
If RUN and ERR turn red, this indicates a fatal event, forcing the bus
Red Fatal event interface to a physically passive state.
Contact Sames technical support.

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ERROR Led Description Comments

OFF Not error No error or no power
State change received from master is not possible due to invalid
Red, blinking Invalid configuration
register or object settings
Slave device application has changed the Ethercat sate
Red, single flash Unsolicited state change
autonomously
Red, double flash Sync manager watchdog event
Device in EXCEPTION STATE or Major internal fault
Red Application controller failure
(combined with a red RUN Led)
Flickering Booting error detected Firmware download failure
Link activity Led

Description Comments
(5) and (6)
OFF No link No link or no power
Green Link sensed, no activity Link sensed, no traffic detected
Green, flickering Link sensed, activity Link sensed, traffic detected

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9.1.5.3. Ethercat settings

The module supports the position addressing mode.
Each device on EtherCAT is associated with an EtherCAT Slave Interface (ESI) file in XML format, which holds a
description of the device and its functions.
Remarks: This configuration file can be downloaded from www.sames.com.
9.2. Data exchange

9.2.1. Exchanging data flags for CC-Link only
The location of the system area is at the very end of the bit area. 16 bits are reserved for this use.
System area RX System area RY
Bit Description Bit
Inocontroller-> PLC PLC -> Inocontroller
15 15
14 14
(Reserved) (Reserved)
13 13
12 12
Normal operation at 1
-for the initial setting: at the rising edge of the PLC
flag "Initial Data Processing complete",
- in operation if there is neither an "Error Status" nor an
11 Remote Ready 11 Reserved
"Error reset request" nor an "Initial Data Setting
Request".
The Inocontroller module takes into account the data
from PLC
Diagnostic events exist – This flag stays high until the
10 Error Status PLC has acknowledged the event through the ‘Error 10 Error Reset Request
Reset Request'
The master PLC asks for an ‘Initial Data Setting
Initial Data Initial Data Setting
9 Request’ 9
Setting Complete Request
Cleared at the falling edge of the PLC request
At startup, the Inocontroller module asks for an "Ini-
Initial Data Process- tial Data Processing Request". Initial Data Processing
8 8
ing Request When it receives the response from the API, the mod- Complete
ule switches to the'Remote READY' state
7 7
6 6
5 5
4 (Reserved) 4
(Reserved)
3 3
2 2
1 1
0 0
Before exchanging process data, the PLC must answer to the ‘Initial Data Processing Request‘ by setting the ‘Initial
Data Processing Complete‘ to 1 in order the communication module of the Inocontroller switches in Remote READY
state.
The Inocontroller module takes then into account the process data from the PLC.

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9.2.2. From PLC to the Inocontroller module

6 words are exchanged from PLC to the Inocontroller module.
Word Label Parameter description Unit Max.
Commands requested by the PLC (see the detailed
0 PLC Command -
description hereafter)
Current Setpoint requested by the PLC.
1 PLC Current Setpoint This setpoint is applied only if the PLC_Control mode is μA 110
active and the HV trigger is activated.
High Voltage Setpoint requested by the PLC.
2 PLC Voltage Setpoint This setpoint is applied only if the PLC_Control mode is kV 100
Injection Setpoint requested by the PLC.
3 PLC injection Setpoint This setpoint is applied only if the PLC_Control mode is Points 100
Dilution Setpoint requested by the PLC.
4 PLC dilution Setpoint This setpoint is applied only if the PLC_Control mode is Points 100
Blowing Setpoint requested by the PLC.
5 PLC blowing Setpoint This setpoint is applied only if the PLC_Control mode is Points 30

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Word 0 PLC Command

15
14
13
12
11
10
9
8
HV trigger start (set to 1)/ stop (set to 0) request.
The request is only taken into account if the PLC control is enabled by the
7 On/OFF trigger Inocontroller and if the HV pilot is requested.
If a manual spray gun is connected, this request must be set to 1 to authorize
control of the HV or acknowledgment of a fault by the spray gun trigger
Cleaning start (set to 1) / stop (set to 0) request.
6 Cleaning ON/OFF The request is only taken into account if the PLC control is enabled by the
Inocontroller and if the cleaning pilot is requested
Request for acknowledgement of resetable faults.
The request is only taken into account on rising edge if the PLC control is
5 Fault acknowledgement
validated by the Inocontroller and if there is no longer a request for trigger
operation or cleaning (by PLC or external)
If a manual spray gun is connected, it is possible to prohibit the local injection
set-point (set to 1)
4 Local setpoint prohibited
Otherwise the operator can modify the injection set-point by simultaneously
pressing the trigger and activating the + or - keys.
The PLC asks to control the cleaning (active if set to 1), to 0 wired control.
3 Cleaning control request The request is only taken into account if the PLC control is enabled by the
Inocontroller
The PLC asks to control the HV (active if set to 1), to 0 wired control
The request is only taken into account if the PLC control is enabled by the
2 HV control request Inocontroller
If a manual spray gun is connected, this request must be set to 1 to authorize
control of the HV or acknowledgment of a fault by the spray gun trigger
1 Spare
0 PLC control request The PLC asks to control the Inocontroller (active if set to 1)

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9.2.3. From Inocontroller to PLC

7 words of feedback are exchanged from Inocontroller to PLC.
Word Label Parameter Description Unit Min.Max.
0 State Status information (see description hereafter) -
1 Fault Fault information (see description hereafter) -
2 HV output current μA 110
3 HV output voltage 0,1*kV 1000
4 Injection flow 0,1*L/min 960
5 Dilution flow 0,1*L/min 610
6 Blowing flow 0,1*L/min 16
Word 0 State State Informations

15 Init mode Software in initialization step
14 Spare
13 High voltage ON High Voltage is effectively active
12 HV request OK The HV request is taken into account by the Inocontroller
External cleaning is requested (1 on the input), it will be taken into account if
11 External cleaning
the PLC has not requested cleaning control
External HV trigger is requested (1 on the input), it will be taken into account
10 External HV trigger
if the PLC has not requested HV control
9 Cleaning request OK The cleaning start request is taken into account by the Inocontroller
A cleaning is in progress (the air controls are at maximum, there is no
8 Cleaning in pogress
controlled HV)
7 Manual spray gun A manual spray gun is connected (if set to 1)
6 Fault with 24V cutoff Resettable fault only after a 24V shutdown
Configured communication
5 The communication module is configured
module
4 Fault A fault is present
3 Wireless control - reserved Control mode by wireless - reserved
2 CAN Control Control mode by the CAN communication
USB Control -
1 Control mode by the USB software - reserved
reserved
0 PLC Control Control mode by the PLC (via the communication module)

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Word 1 Fault Fault Informations

15 1 - Program fault
14 2 - +24V power supply
13 Spare
12 17 - Absence of control mode fault
11 Spare
10 34 - Blowing fault
9 33 - Dilution fault
8 32 - Injection fault
see § 8.1 page 22
7 5 - Voltage coherence fault
6 22 - Safe shutdown fault
5 21- Bus power fault
4 37 - Spray gun or projector connector fault
3 28 - Temperature fault
2 24 - Trigger request at startup
1 29- HVU link fault
0 30 - Internal BUS fault

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10. CAN Communication with PLC

10.1. Characteristics
In network mode, it is possible to communicate with the Inocontroller module in CAN (to be connected to connector
B).
It is necessary to configure the address of the Inocontroller and the communication speed
The node address is set by microswitches S1 on the module.
For example, to set the node address to the value 23, microswitches 1, 2, 3 and 5
must be set to ON state and the others to OFF state.
The communication speed is defined by the first 4 microswitches of S2.
Speed in Kbits/s S2 S2#1 S2#2 S2#3 S2#4

10 0 0 0 0 0
20 1 1 0 0 0
50 2 0 1 0 0
100 3 1 1 0 0
125 4 0 0 1 0
250 5 1 0 1 0
500 6 0 1 1 0
1000 7 1 1 1 0
It is a CAN2.0A version, standard format (11-bit identifier).
The CAN uses a linear bus terminated at each end by a 120 resistor ? (which is not integrated in the Inocontroller
module).
The Inocontroller module must receive regularly, about every 100ms, an exchange otherwise a fault "17 - Absence
of control mode fault" appears after 1s.

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10.2. Data exchange
10.2.1. From CAN to the Inocontroller module

8 bytes are exchanged from a CAN module to the Inocontroller
Byte Label Description Unit Max.
Commands requested by the CAN (see the detailed
0 CAN Command -
description hereafter)
Current set-point requested by the CAN.
1 CAN Current Setpoint This set-point is applied only if the CAN_Control mode is μA 110
High voltage set-point requested by the CAN.
2 CAN Voltage Setpoint This set-point is applied only if the CAN_Control mode is kV 100
Injection set-point requested by the CAN.
3 CAN Injection Setpoint This set-point is applied only if the CAN_Control mode is Point 100
Dilution set-point requested by the CAN.
4 CAN Dilution Setpoint This set-point is applied only if the CAN_Control mode is Point 100
Blowing set-point requested by the CAN.
5 CAN Blowing Setpoint This set-point is applied only if the CAN_Control mode is Point 30
6 Spare
7 Spare
Byte 0 CAN Command

HV trigger start (set to 1)/ stop (set to 0) request.
The request is only taken into account if the CAN control is enabled by the Inocontroller
7 ON/OFF trigger and if the HV pilot is requested.
If a manual spray gun is connected, this request must be set to 1 to authorize control of the
HV or acknowledgment of a fault by the spray gun trigger
Cleaning start (set to 1) / stop (set to 0) request.
6 Cleaning ON/OFF The request is only taken into account if the CAN control is enabled by the Inocontroller
and if the cleaning pilot is requested
Request for acknowledgment of resetable faults
The request is only taken into account on rising edge if the CAN control is validated by the
5 Fault acknowledgment
Inocontroller and if there is no longer a request for trigger operation or cleaning
(by the CAN or external)
If a manual spray gun is connected, it is possible to prohibit the local injection set-point (set
Local set-point to 1)
4
prohibited Otherwise the operator can modify the injection set-point by simultaneously pressing the
trigger and activating the + or - keys.
The CAN asks to control the cleaning (active if set to 1), to 0 wired control.
3 Cleaning control request
The CAN asks to control the HV (active if set to 1), to 0 wired control
2 HV control request
If a manual spray gun is connected, this request must be set to 1 to authorize control of the
HV or acknowledgment of a fault by the spray gun trigger
1
0 CAN control request The CAN asks to control the Inocontroller (active if set to 1)

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10.2.2. From Inocontroller to a CAN module

8 bytes of feedback are exchanged from Inocontroller to a CAN module
Byte Label Parameter Description Unit Max.
0 Status 1 Status information 1(see description hereafter) - -
1 Status 2 Status information 2 (see description hereafter) - -
2 Fault 1 Fault information 1 (see description hereafter) - -
3 Fault 2 Fault information 2 (see description hereafter) - -
4 HV ouput current μA 110
5 HV ouput voltage kV 100
Bit 7 =0 Injection on 7bits in l/min L/min or 96 l/min and
6 Injection or Blowing
Bit 7=1 soufflage on 7 bits in dl/min dl/min 16 dl/min
Bit 7 =0 dilution on 7bits in L/min
7 Dilution L/min 61
Bit 7 =1 Spare
Byte 0 Status 1 Status information 1

7 Init mode Software in initialization step
6 Spare
5 High voltage ON High Voltage is effectively active
4 HV request OK The HV request is taken into account by the Inocontroller
External cleaning is requested (1 on the input), it will be taken into account
3 External cleaning
if the PLC has not requested cleaning control
External HV trigger is requested (1 on the input), it will be taken into
2 External HV trigger
account if the PLC has not requested HV control
1 Cleaning request OK The cleaning start request is taken into account by the Inocontroller
A cleaning is in progress (the air controls are at maximum, there is no con-
0 Cleaning in progress
trolled HV)
Byte 1 Status 2 Status information 2

7 Manual spray gun A manual spray gun is connected (if set to 1)
6 Fault with 24V cutoff Resettable fault only after a 24V shutdown
Configured communication
5 The communication module is configured
module
4 Fault A fault is present
3 Wireless control - reserved Control mode by wireless - reserved
2 CAN Control Control mode by the CAN communication
1 USB Control - reserved Control mode by the USB software - reserved
0 PLC Control Control mode by the PLC (via the communication module)

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Byte 2 Fault 1 Fault information 1

7 1- Program fault
6 2- +24V power supply
5 Spare
4 17- Absence of control mode fault
see § 8.1 page 22
3 Spare
2 34- Blowing fault
1 33- Dilution fault
0 32 - Injection fault
Byte 3 Fault 2 Fault information 2

7 5- Voltage coherence fault
6 22- Safe shutdown fault
5 21-Bus power fault
4 37 - Spray gun or projector connector fault
see § 8.1 page 22
3 28- Temperature fault
2 24- Trigger request at startup
1 29- HVU link fault
0 30-Internal bus fault

DRT1734
C - 2022/12
11. Spare parts list

The spare parts are classified in 2 different types:
• 1st emergency parts:
The 1st emergency parts are strategic components which are not necessarily consumables but which in case
of failure prohibit the operation of the equipment.
Depending on the production line's commitment and the production rates imposed, the first emergency parts
are not necessarily kept available in the customer's stock.
Indeed, if an interruption of the production flow is possible, storage is not necessary.
On the other hand, if the stop is not possible, the 1st emergency parts will be kept in stock.
• Wearing parts:
Wearing parts are consumable components such as O-rings that undergo regular degradation over time during
normal operation of the installation. It is therefore advisable to replace them according to a defined frequency
and adapted to the operating time of the installation.
The wearing parts must therefore be kept in the customer's stock.
To guarantee an optimal assembly, spare parts must be stored in a temperature close to their
temperature of use. Should the opposite occur, a sufficient waiting time must be observed
before the installation, so that all the elements are assembled in the same temperature.

DRT1734
C - 2022/12
Level
Unit of
Item Part Number Description Qty Spare parts
sale
(*)
Inocontroller control module
1 910028596 1 1 -
(Connection kit included)
Connection kit for Inocontroller including
2 pt connector (5.08 mm pitch)
10 pt connector
2 110002820 Screw 1 1 -
Shielding collar
Micro USB Dust Cap
Network module plastic cover
Other associated modules (not shown)
110002470 Ethernet IP communication module 1 1 -
110002391 Profinet communication module 1 1 -
110002472 CC-link communication module 1 1 -
110002473 Profibus communication module 1 1 -
110002640 Ethercat communication module 1 1 -
(*)
Level 1: 1st emergency parts
Level 2: Wearing parts

DRT1734
C - 2022/12
12. Revision index History
Created by: Checked by: H. Brochier-Cendre Approuved by: S. Court

Date By: Index Purpose of the modification and location
2020/03 S. Court A First Issue
Addition of CSA marking + applicable standards, § 1. 3
2020/09 S. Court B Addition of general characteristics and modification of § 10
CAN communication
UKCA and QPS Marking
Transfer of CSA certification to QPS
Change of identity and logo
2022/12 O.Aubin C
Update of the graphic charter
Added Inhibition of air flow monitoring § 4.6
Update of the fault management § 8.1

Sames
13, Chemin de Malacher
38240 Meylan - France
 33 (0)4 76 41 60 60 www.sames.com

Inocontroller Control Module Instructions Manual Sames DRT7134 Uk

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Inocontroller

© Sames 2020 - translation of the original version

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Certification and referencing

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1. Health and safety instructions

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1.3. Meaning of pictograms

Warning Warning Warning Warning General warning

Warning Warning Warning for Warning Warning

Warning Warning No access for Wear ear Wear a face

Opaque eye General mandatory Connect an Refer to

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1.4. Precautions for Use

The control module Inocontroller must not be installed in an explosive atmosphere.

Equipment performance is only guaranteed if original spare parts distributed by Sames

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This equipment may be hazardous if it is not used, disassembled and reassembled in

• The Inocontroller control module must not be installed outdoors.

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The Inocontroller is controlled by a PLC network or via a CAN link.

PLC + 24VDC LPS

Network Communication Air supply Powder supply Inogun A

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Dimensions Width 105.2 mm x height 270 mm x depth 208 mm (without connector )

Ambient temperature during operations 0° C min. -> 40°C max.

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3.2. Electrical characteristics

3.3. Air compressed quality

Non-compliance with these characteristics may result in incorrect operation of

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4. Operating principle of the Inocontroller

Item Icons Description Characteristics

2 Blowing air Hose Dia.: 4/6 rilsan

3 Dilution air Hose Dia.: 4/6 rilsan

4 Injection air Hose Dia.: 6/8 rilsan

5 Air supply Hose Dia.: 8/10 rilsan

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High voltage control and spraying:

4.3. State of the Inocontroller

Symbol Indicator Status Indication

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4.4. Configuration of the communication network

S1: Configuration S2: Speed

4.4.1. Network address

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4.4.2. Network speed

4.6. Inhibition of injection air flow monitoring

Micro-switch S2#7 is used to disable the monitoring of the

If the micro-switch is in the OFF position, monitoring is active

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Pin Description Designation Characteristics

5.2. Connector B - I/O (Input/Output)

Pin Designation Description Characteristics

5.3. Low voltage connector to Inogun A projector or Inogun M spray gun

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