1081748A04 - Prodigy Automatic System HDLV Pump Panel

Prodigy� Automatic System HDLV� Pump Panel

Customer Product ManualPart 1081748A04

Issued 01/10

NORDSON CORPORATION • AMHERST, OHIO • USA

For parts and technical support, call the Finishing Customer Support Center at (800) 433-9319.

Check http://emanuals.nordson.com/finishing for the latest version.This document is subject to change without notice.

Nick.Klasovsky

Rectangle

Part 1081748A04 � 2010 Nordson Corporation

Table of Contents

Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Qualified Personnel 1. . . . . . . . . . . . . . . . . . . . . . . . . Intended Use 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regulations and Approvals 1. . . . . . . . . . . . . . . . . . Personal Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . Fire Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounding 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Action in the Event of a Malfunction 2. . . . . . . . . . . Disposal 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel Components 4. . . . . . . . . . . . . . . . . . . . . . . . . .

External Components 4. . . . . . . . . . . . . . . . . . . . . . . Internal Components 5. . . . . . . . . . . . . . . . . . . . . . .

Pump Panel Configuration and Layout 6. . . . . . . . Network Switch Settings 6. . . . . . . . . . . . . . . . . . . .

SW1 Settings 6. . . . . . . . . . . . . . . . . . . . . . . . . . . SW2 Settings 6. . . . . . . . . . . . . . . . . . . . . . . . . . .

Typical Pump Panel Layout 7. . . . . . . . . . . . . . . . . . Pneumatic Diagrams 8. . . . . . . . . . . . . . . . . . . . . . . . .

Pump Panel to Pump Manifolds 8. . . . . . . . . . . . . . Pump Manifolds to Circuit Board 9. . . . . . . . . . . . .

Wiring Diagrams 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Board to Pump Manifolds 10. . . . . . . . . . . . . Network and Power Wiring Diagram 11. . . . . . . . . .

Parts 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Illustrated Parts List 12. . . . . . . . . . . . . . . Internal Pump Panel Replacement Parts 12. . . . . . External Pump Panel Replacement Parts 14. . . . . .

Contact UsNordson Corporation welcomes requests for information, comments, andinquiries about its products. General information about Nordson can befound on the Internet using the following address:http://www.nordson.com.Address all correspondence to:

Nordson CorporationAttn: Customer Service555 Jackson StreetAmherst, OH 44001

NoticeThis is a Nordson Corporation publication which is protected by copyright.Original copyright date 2007. No part of this document may bephotocopied, reproduced, or translated to another language without theprior written consent of Nordson Corporation. The information containedin this publication is subject to change without notice.

Trademarks

HDLV, Nordson ,the Nordson logo, and Prodigy are registered trademarksof Nordson Corporation.

Change Record i

Part 1081748A04� 2010 Nordson Corporation

Change RecordRevision Date Change

A03 12/09 Removed manifold assembly part number and added reference to thepump, manifold, and circuit board manual 1081195.

A04 01/10 Replaced solenoid valve 1027412 with 1099534.

Change Recordii


Prodigy� Automatic System HDLV� Pump Panel 1


Prodigy� Automatic System HDLV� Pump Panel

Safety Read and follow these safety instructions. Task-and equipment-specific warnings, cautions, andinstructions are included in equipmentdocumentation where appropriate.

Make sure all equipment documentation, includingthese instructions, is accessible to all personsoperating or servicing equipment.

Qualified Personnel

Equipment owners are responsible for making surethat Nordson equipment is installed, operated, andserviced by qualified personnel. Qualifiedpersonnel are those employees or contractors whoare trained to safely perform their assigned tasks.They are familiar with all relevant safety rules andregulations and are physically capable ofperforming their assigned tasks.

Intended Use

Use of Nordson equipment in ways other thanthose described in the documentation supplied withthe equipment may result in injury to persons ordamage to property.

Some examples of unintended use of equipmentinclude

� using incompatible materials

� making unauthorized modifications

� removing or bypassing safety guards orinterlocks

� using incompatible or damaged parts

� using unapproved auxiliary equipment

� operating equipment in excess of maximumratings

Regulations and Approvals

Make sure all equipment is rated and approved forthe environment in which it is used. Any approvalsobtained for Nordson equipment will be voided ifinstructions for installation, operation, and serviceare not followed.

All phases of equipment installation must complywith all federal, state, and local codes.

Personal Safety

To prevent injury follow these instructions.

� Do not operate or service equipment unless youare qualified.

� Do not operate equipment unless safetyguards, doors, or covers are intact andautomatic interlocks are operating properly. Donot bypass or disarm any safety devices.

� Keep clear of moving equipment. Beforeadjusting or servicing any moving equipment,shut off the power supply and wait until theequipment comes to a complete stop. Lock outpower and secure the equipment to preventunexpected movement.

� Relieve (bleed off) hydraulic and pneumaticpressure before adjusting or servicingpressurized systems or components.Disconnect, lock out, and tag switches beforeservicing electrical equipment.

Prodigy� Automatic System HDLV� Pump Panel2


� Obtain and read Material Safety Data Sheets(MSDS) for all materials used. Follow themanufacturer’s instructions for safe handlingand use of materials, and use recommendedpersonal protection devices.

� To prevent injury, be aware of less-obviousdangers in the workplace that often cannot becompletely eliminated, such as hot surfaces,sharp edges, energized electrical circuits, andmoving parts that cannot be enclosed orotherwise guarded for practical reasons.

Fire Safety

To avoid a fire or explosion, follow theseinstructions.

� Do not smoke, weld, grind, or use open flameswhere flammable materials are being used orstored.

� Provide adequate ventilation to preventdangerous concentrations of volatile materialsor vapors. Refer to local codes or your materialMSDS for guidance.

� Do not disconnect live electrical circuits whileworking with flammable materials. Shut offpower at a disconnect switch first to preventsparking.

� Know where emergency stop buttons, shutoffvalves, and fire extinguishers are located. If afire starts in a spray booth, immediately shut offthe spray system and exhaust fans.

� Clean, maintain, test, and repair equipmentaccording to the instructions in your equipmentdocumentation.

� Use only replacement parts that are designedfor use with original equipment. Contact yourNordson representative for parts informationand advice.

Grounding

WARNING: Operating faultyelectrostatic equipment is hazardous andcan cause electrocution, fire, orexplosion. Make resistance checks partof your periodic maintenance program. Ifyou receive even a slight electrical shockor notice static sparking or arcing, shutdown all electrical or electrostaticequipment immediately. Do not restartthe equipment until the problem hasbeen identified and corrected.

Grounding inside and around the booth openingsmust comply with NFPA requirements for Class 2,Division 1 or 2 Hazardous Locations. Refer toNFPA 33, NFPA 70 (NEC articles 500, 502, and516), and NFPA 77, latest conditions.

� All electrically conductive objects in the sprayareas shall be electrically connected to groundwith a resistance of not more than 1 megohmas measured with an instrument that applies atleast 500 volts to the circuit being evaluated.

� Equipment to be grounded includes, but is notlimited to, the floor of the spray area, operatorplatforms, hoppers, photoeye supports, andblow-off nozzles. Personnel working in thespray area must be grounded.

� There is a possible ignition potential from thecharged human body. Personnel standing on apainted surface, such as an operator platform,or wearing non-conductive shoes, are notgrounded. Personnel must wear shoes withconductive soles or use a ground strap tomaintain a connection to ground when workingwith or around electrostatic equipment.

� Operators must maintain skin-to-handle contactbetween their hand and the gun handle toprevent shocks while operating manualelectrostatic spray guns. If gloves must beworn, cut away the palm or fingers, wearelectrically conductive gloves, or wear agrounding strap connected to the gun handle orother true earth ground.

� Shut off electrostatic power supplies andground gun electrodes before makingadjustments or cleaning powder spray guns.

� Connect all disconnected equipment, groundcables, and wires after servicing equipment.

Action in the Event of a Malfunction

If a system or any equipment in a systemmalfunctions, shut off the system immediately andperform the following steps:

� Disconnect and lock out electrical power. Closepneumatic shutoff valves and relieve pressures.

� Identify the reason for the malfunction andcorrect it before restarting the equipment.

Disposal

Dispose of equipment and materials used inoperation and servicing according to local codes.



Description The pump panel is the central electrical andpneumatic enclosure for Prodigy HDLV pumpsused with Prodigy Automatic Spray Guns. Thepanels are installed on the sides of the ProdigyPowder Feed Center. The pump panels areavailable in four, six, and eight pumpconfigurations. Each panel houses the ProdigyHDLV pumps, pump manifolds and pump controlboard, air filter and pneumatic controls, and DCpower supply.

This manual provides panel wiring and pneumaticdiagrams and replacement parts only. Refer to thepowder feed center manual for operationinstructions.

Refer to the following manuals for additional repairand parts information:

1081195 HDLV Pump1062382 HDLV Pump Manifold and Circuit Board

Figure 1 Prodigy Automatic System HDLV PumpPanel (Eight-Pump Panel Shown)



Panel Components External Components

7

2

3

4

1

5

6

8

10

9

11

Figure 2 External Pump Panel Components (Eight-Pump Panel Shown)

1. Prodigy HDLV Pumps2. IN Filtered air supply

(pump assist/pattern air flow)3. IN Air supply (pinch and vacuum)

4. Pattern air out5. INPUT power6. NET/PWR to feed center network

junction box7. Vacuum exhaust mufflers

8. Purge pilot−bottom bank ofpumps

9. Purge pilot−top bank ofpumps

10. Accumulator tank11. Purge air tubing/Y-connectors



Internal Components

1

2

3

4

5

6 7 98

10

1112

Figure 3 Internal Pump Panel Components (Eight-Pump Panel Shown)

1. Pump control manifolds2. Pump circuit boards3. Power and network terminal strip4. Filter

5. Fuses6. 145 W power supply7. Vacuum air regulator

(50 psi/3.4 bar)8. Pinch high air regulator

(70 psi/4.8 bar)

9. Pinch low air regulator(35 psi/2.4 bar)

10. Pump assist/pattern air flowregulator

11. Pinch select manifold12. Purge pilot manifold



Pump Panel Configuration and Layout

The pump panel is available in 4-, 6-, and 8-pump configurations. Up to four pump panels may beconnected to a single powder feed center.

Network Switch Settings Use the following guidelines to set switches SW1and SW2 on each HDLV pump circuit board.

SW1 Settings

SW1 identifies the sequential nodeaddress of the circuit board.

Each circuit board controls two pumps. Refer tothe following chart and Figure 5 for a description ofhow to set SW1.

SwitchPosition

Pumps Controlled

Left Side ofFeed Center

Right Side ofFeed Center

1 1, 2 17, 18

2 3, 4 19, 20

3 5, 6 21, 22

4 7, 8 23 ,24

5 9, 10 25, 26

6 11, 12 27, 28

7 13, 14 29, 30

8 15, 16 31, 32

SW2 Settings

See Figure 4. SW2 identifies the pump paneladdress and the type of gun (manual or automatic)that is controlled by the circuit board.

Switch Position

1Down: Panels 1 and 2 (Guns 1−16)

Up: Panels 3 and 4 (Guns 17−18)

2 Down (not used)

3 Down (not used)

4Down: Automatic Guns

Up: Manual Guns

1 2 3

OPEN

4

Gun Group

= Guns 17−32

= Guns 1−16

1

2

Not Used

3

Gun Type

= Manual

= Automatic

4

Figure 4 SW2 Settings



Typical Pump Panel Layout

Figure 5 shows the layout and switch settings of atypical powder feed center. The example shows alayout that controls 28 automatic and four manualpowder spray guns.

Pump panel layout typically follows theseguidelines:

� A powder feed center may have up to fourseparate pump panels.

� Each pump panel may control up to eightpumps.

� One circuit board controls two pumps.

� Manual guns are typically connected to the lastpumps in the feed center.

� The network must be terminated at the lastcircuit board in the feed center.

W1CAN BUS TERM

A8 A7 A6 A5

A4 A3 A2 A1

A16 A15 A14 A13

A12 A11 A10 A9

A24 A23 A22 A21

A20 A19 A18 A17

M4 M3

A28 A27 A26 A25

2

Left Side of Feed Center

A1

1

Pump Manifold(A=Automatic, M=Manual)

SW1

SW2

1 Network Termination:Jumper across pins 1 and 2on last board in feed center

Right Side of Feed Center

1

4 3

2 1

4 3

6 5

7 8

6 5

8 7

Legend

M2 M1

Figure 5 Typical Pump Panel Layout



Pneumatic Diagrams Pump Panel to Pump Manifolds

Figure 6 Pump Panel Pneumatic Diagram − Pump Panel to Pump Manifolds (Eight-Pump Panel Shown)

Air Pressure Settings

Function Setting

Vacuum 3.4 bar (50 psi)

Pinch High 4.8 bar (70 psi)

Pinch Low 2.4 bar (35 psi)



Pump Manifolds to Circuit Board

8 7 6 5 4 3 2 1

(BOTTOM VIEW)

56

8 7

(BOTTOM VIEW)

3 4

21

PUMP/MANIFOLD

1

PUMP/MANIFOLD

2

8

7 5

6

13

4 2

INSTALL TUBING BEFOREMOUNTING BOARDS

SW1

SW2

Figure 7 Pump Panel Pneumatic Diagram − Pump Manifolds to Circuit Board



Wiring Diagrams Circuit Board to Pump Manifolds

SW1

+24VDC

BLACKBLACK

RED

BLU

EB

RN

GR

N/Y

EL

BLU

E

BR

NG

RN

/YE

L

+24VDC

BLACK

BLU

EB

RN

GR

N/Y

EL

RED

1

8

1

4 3 2 1

8

1

J3PATT B

SOL

1

J4PUMP B SOL

1 1

J2PUMP A

SOL

1

J1PATT ASOL

1

P4

J5

P2PUMP

B

P1PUMP

A

P5CANOUT

P6CAN IN

W1CAN BUS

TERM

1 1

P3DC

POWER

GR

N/Y

EL

BR

NB

LUE

+24VDC BLUE

GND GRN/YEL

PATTERN BRN

+24VDC BLUE

GND GRN/YEL

FLOW BRN

SOL.7SOL.1

HDLV PUMP CONTROL MANIFOLD

GND GRN/YELFLOW BRN

+24VDC BLUE

GND GRN/YEL

FLOW BRN

+24VDC BLUE

5

3

7

2

4

6

1

3

5

6

4

1

2

7

SOL.2

SOL.5

SOL.3

SOL.4

SOL.6SOL.7

SOL.2

SOL.5

SOL.4

SOL.1

SOL.3

SOL.6

2 HDLV PUMP CONTROL MANIFOLD1

TO HDLV PUMPCONTROL MANIFOLD 2

SOLENOIDS 1 − 7

TO HDLV PUMPCONTROL MANIFOLD 1

SOLENOIDS 1 − 7

PRODIGY

DUAL PUMP

CONTROLLER

SW2

Figure 8 Circuit Board to Pump Manifolds Wiring Diagram



Network and Power Wiring Diagram

BR

OW

N

BLU

E

145W

PO

WE

R S

UP

PLY

BLA

CK

GR

AY

OR

AN

GE

RE

D

SK

2

456 23 1

L1 (

5)S

K1 L2

(3)

BLA

CK

1

81

43

2181

J3

1

J4

11

J2

1

J1

1

P4

J5

P2

P1

P5

P6

W1

11

P3

PINCH 1PINCH 2

PURGE 1PURGE 2

RE

D

REDBLACK

REDBLACK

GRAYBLACK

RED

ORANGE

PIN

CH

SE

LEC

TM

AN

IFO

LD

REDBLACK

REDBLACK

PU

RG

E P

ILO

TM

AN

IFO

LD

TERMINALBLOCK

SW

2

SW

1

P3

11

1

W1

P4

1

8

P6

P5

11

11

41

23

SW

2

SW

1

8

11

J3

W1

1

P4

P6

P5

11

P3

32

14

SW

2

P5

P4

1

P6

1

J2P

2

1

1 8J3

J4

J5

11

1

J1

SW

1

P1

1

81

J4P

2

1J5

811

1

P3

W1

1

14

32S

W2

P1

J1J21

1

81 SW

1

REDBLACK

ORANGEGRAY

GR

AY

GR

AY

BLA

CK

RE

D

OR

AN

GE

BLA

CK

OR

AN

GE

RE

D

REDBLACK

ORANGEGRAY

RED

GRAYORANGE

BLACK

BLA

CK

RE

D

22”

CU

TLE

NG

TH

FU

SE

HO

LDE

RS

106

8938

FU

SE

S 9

3914

4

BROWNBLUE

GRN/YEL

L (L

1 −

HO

T)

N (

L2 −

NE

UT

RA

L)

BR

OW

N

BLU

E

BLUE

BROWN

L1L2

GR

EE

N/Y

EL

FILTER334805

1

4

52

3

BLU

E

BR

OW

N

HA

RN

ES

S,P

UM

PC

ON

TR

OLL

ER

,FIL

TE

R

PO

WE

R S

UP

PLY

EN

D V

IEW

BO

AR

D 2

BO

AR

D 1

BO

AR

D 3

BO

AR

D 4

SE

E S

WIT

CH

DE

TAIL

SC

OR

RE

SP

ON

DS

WIT

HB

OA

RD

NU

MB

ER

AD

JUS

T V

OLT

AG

ET

O 2

4.0V

0.

1V

GR

N/Y

EL

GN

D (

1)

CA

N N

ET

WO

RK

IN

(FR

OM

IC

ON

TR

OL

OR

PR

EV

IOU

S P

UM

P P

AN

EL)

CA

N N

ET

WO

RK

OU

T

(TO

NE

XT

PU

MP

PA

NE

L O

R M

AN

UA

L G

UN

INT

ER

FAC

E)

GRN/YEL

1

1

W1

CA

N B

US

TE

RM

JUM

PE

R P

INS

2 &

3T

YP.

AL

LB

OA

RD

S

Figure 9 Network and Power Wiring Diagram



Parts

To order parts, call the Nordson Finishing Customer Support Center at (800) 433-9319 or contact your localNordson representative.

Internal Pump Panel Replacement Parts See Figure 10.

Item Part Description Quantity Note1 - - - - - - MANIFOLD ASSEMBLY, HDLV pump control AR A, C

2 1092274 KIT, PCA replacement, Prodigy pump control AR B

3 334805 FILTER, line, RFI, power, 10 A 1

4 1068938 FUSE BLOCK, pump control 1

5 939144 � FUSE, 4amp, slo blow, fast acting, 250 V 2

6 1069113 POWER SUPPLY, 145 Watt 1

7 1077780 REGULATOR ASSEMBLY, 3, Prodigy 1

8 1064135 � REGULATOR, manifold, modular style 3

9 1065536 � GAUGE, air, 0−100 psi, 0.7 bar, 1/8 in. RPT 3

10 1033878 REGULATOR, rolling diaphragm, 0−120 psi,1/2 in.-NPT

1

11 1099534 VALVE, solenoid, 3 port, 24 V, with adapter 4 D

12 1062364 MANIFOLD, 2 station, 6-mm tube x 1/8-in. RPT 2

NOTE A: When replacing manifold, perform calibration procedure as described in Manual Gun Controller manual.

B: When replacing the circuit board, refer to Pump Panel Configuration and Layout on page 6 for switchsettings. Also perform calibration procedure as described in Manual Gun Controller manual.

C: For manifold assembly part numbers, refer to manual 1081195.

D: If using an old harness with 3 positions, use the supplied adapter. If using a new harness with 2 positions,the supplied adapter can be discarded.

NS: Not Shown

AR: As Required



1

2

3

4, 5

6 7

10

12

11

8

9

Figure 10 Internal Pump Panel Replacement Parts (Eight-Pump Panel Shown)



External Pump Panel Replacement Parts See Figure 11.

Item Part Description Quantity Note1 1040664 MUFFLER, male, 1/4-in. BPST AR2 1081194 PUMP ASSEMBLY, HDLV AR3 1087160 TANK, accumulator, pump controller 1

AR: As Required

2

1

3

Figure 11 External Pump Panel Replacement Parts (Eight-Pump Panel Shown)

Coating and Finishing Systems GroupNordson CorporationAmherst, Ohio, USA

DECLARATION of CONFORMITY

PRODUCT:

Prodigy HDLV Automatic Pump System, 4-8 ApplicatorsAutomatic Pump System for use with Automatic Applicators and Prodigy iControl

APPLICABLE DIRECTIVES:

98/37/EEC (Machinery)2006/95/EC (Low-V oltage Directive)2004/108/EEC (Elecromagnetic Compatibility Directive)87/404/EEC (Simple Pressure Vessel Directive)

STANDARDS USED TO VERIFY COMPLIANCE:

IEC60417 EN61000-6-2 NFPA79EN12100 EN61000-6-3EN60204 EN55011

PRINCIPLES:

This product has been manufactured according to good engineering practice.The product specified conforms to the directive and standards described above.

Quality Certificate:

DNV ISO9001:2000

Date: 30 April 2008

Joseph SchroederEngineering Manager, Finishing Product Development Group

Nordson Corporation � Westlake, Ohio DOC14020A03

1081748A04 - Prodigy Automatic System HDLV Pump Panel

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Transcript of 1081748A04 - Prodigy Automatic System HDLV Pump Panel