Nordson PRODIGY Reference guide

ProdigyrAutomatic System
HDLVrPump Panel
Customer Product Manual
Part 1081748A04
Issued 01/10
NORDSON CORPORATION •AMHERST, OHIO •USA
For parts and technical support, call the
Finishing Customer Support Center at [phone].
Check http://emanuals.nordson.com/finishing for the latest version.
This document is subject to change without notice.

Part 1081748A04 E2010 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 Us
Nordson Corporation welcomes requests for information, comments, and
inquiries about its products. General information about Nordson can be
found on the Internet using the following address:
http://www.nordson.com.
Address all correspondence to:
Nordson Corporation
Attn: Customer Service
555 Jackson Street
Amherst, OH 44001
Notice
This is a Nordson Corporation publication which is protected by copyright.
Original copyright date 2007. No part of this document may be
photocopied, reproduced, or translated to another language without the
prior written consent of Nordson Corporation. The information contained
in this publication is subject to change without notice.
Trademarks
HDLV, Nordson ,the Nordson logo, and Prodigy are registered trademarks
of Nordson Corporation.

Change Record i
Part 1081748A04
E2010 Nordson Corporation
Change Record
Revision Date Change
A03 12/09 Removed manifold assembly part number and added reference to the
pump, manifold, and circuit board manual 1081195.
A04 01/10 Replaced solenoid valve 1027412 with 1099534.

Change Record
ii
Part 1081748A04 E2010 Nordson Corporation

ProdigyrAutomatic System HDLVrPump Panel 1
Part 1081748A04
E2010 Nordson Corporation
ProdigyrAutomatic System HDLVrPump Panel
Safety
Read and follow these safety instructions. Task-
and equipment-specific warnings, cautions, and
instructions are included in equipment
documentation where appropriate.
Make sure all equipment documentation, including
these instructions, is accessible to all persons
operating or servicing equipment.
Qualified Personnel
Equipment owners are responsible for making sure
that Nordson equipment is installed, operated, and
serviced by qualified personnel. Qualified
personnel are those employees or contractors who
are trained to safely perform their assigned tasks.
They are familiar with all relevant safety rules and
regulations and are physically capable of
performing their assigned tasks.
Intended Use
Use of Nordson equipment in ways other than
those described in the documentation supplied with
the equipment may result in injury to persons or
damage to property.
Some examples of unintended use of equipment
include
Susing incompatible materials
Smaking unauthorized modifications
Sremoving or bypassing safety guards or
interlocks
Susing incompatible or damaged parts
Susing unapproved auxiliary equipment
Soperating equipment in excess of maximum
ratings
Regulations and Approvals
Make sure all equipment is rated and approved for
the environment in which it is used. Any approvals
obtained for Nordson equipment will be voided if
instructions for installation, operation, and service
are not followed.
All phases of equipment installation must comply
with all federal, state, and local codes.
Personal Safety
To prevent injury follow these instructions.
SDo not operate or service equipment unless you
are qualified.
SDo not operate equipment unless safety
guards, doors, or covers are intact and
automatic interlocks are operating properly. Do
not bypass or disarm any safety devices.
SKeep clear of moving equipment. Before
adjusting or servicing any moving equipment,
shut off the power supply and wait until the
equipment comes to a complete stop. Lock out
power and secure the equipment to prevent
unexpected movement.
SRelieve (bleed off) hydraulic and pneumatic
pressure before adjusting or servicing
pressurized systems or components.
Disconnect, lock out, and tag switches before
servicing electrical equipment.

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Part 1081748A04 E2010 Nordson Corporation
SObtain and read Material Safety Data Sheets
(MSDS) for all materials used. Follow the
manufacturer’s instructions for safe handling
and use of materials, and use recommended
personal protection devices.
STo prevent injury, be aware of less-obvious
dangers in the workplace that often cannot be
completely eliminated, such as hot surfaces,
sharp edges, energized electrical circuits, and
moving parts that cannot be enclosed or
otherwise guarded for practical reasons.
Fire Safety
To avoid a fire or explosion, follow these
instructions.
SDo not smoke, weld, grind, or use open flames
where flammable materials are being used or
stored.
SProvide adequate ventilation to prevent
dangerous concentrations of volatile materials
or vapors. Refer to local codes or your material
MSDS for guidance.
SDo not disconnect live electrical circuits while
working with flammable materials. Shut off
power at a disconnect switch first to prevent
sparking.
SKnow where emergency stop buttons, shutoff
valves, and fire extinguishers are located. If a
fire starts in a spray booth, immediately shut off
the spray system and exhaust fans.
SClean, maintain, test, and repair equipment
according to the instructions in your equipment
documentation.
SUse only replacement parts that are designed
for use with original equipment. Contact your
Nordson representative for parts information
and advice.
Grounding
WARNING: Operating faulty
electrostatic equipment is hazardous and
can cause electrocution, fire, or
explosion. Make resistance checks part
of your periodic maintenance program. If
you receive even a slight electrical shock
or notice static sparking or arcing, shut
down all electrical or electrostatic
equipment immediately. Do not restart
the equipment until the problem has
been identified and corrected.
Grounding inside and around the booth openings
must comply with NFPA requirements for Class 2,
Division 1 or 2 Hazardous Locations. Refer to
NFPA 33, NFPA 70 (NEC articles 500, 502, and
516), and NFPA 77, latest conditions.
SAll electrically conductive objects in the spray
areas shall be electrically connected to ground
with a resistance of not more than 1 megohm
as measured with an instrument that applies at
least 500 volts to the circuit being evaluated.
SEquipment to be grounded includes, but is not
limited to, the floor of the spray area, operator
platforms, hoppers, photoeye supports, and
blow-off nozzles. Personnel working in the
spray area must be grounded.
SThere is a possible ignition potential from the
charged human body. Personnel standing on a
painted surface, such as an operator platform,
or wearing non-conductive shoes, are not
grounded. Personnel must wear shoes with
conductive soles or use a ground strap to
maintain a connection to ground when working
with or around electrostatic equipment.
SOperators must maintain skin-to-handle contact
between their hand and the gun handle to
prevent shocks while operating manual
electrostatic spray guns. If gloves must be
worn, cut away the palm or fingers, wear
electrically conductive gloves, or wear a
grounding strap connected to the gun handle or
other true earth ground.
SShut off electrostatic power supplies and
ground gun electrodes before making
adjustments or cleaning powder spray guns.
SConnect all disconnected equipment, ground
cables, and wires after servicing equipment.
Action in the Event of a Malfunction
If a system or any equipment in a system
malfunctions, shut off the system immediately and
perform the following steps:
SDisconnect and lock out electrical power. Close
pneumatic shutoff valves and relieve pressures.
SIdentify the reason for the malfunction and
correct it before restarting the equipment.
Disposal
Dispose of equipment and materials used in
operation and servicing according to local codes.

ProdigyrAutomatic System HDLVrPump Panel 3
Part 1081748A04
E2010 Nordson Corporation
Description
The pump panel is the central electrical and
pneumatic enclosure for Prodigy HDLV pumps
used with Prodigy Automatic Spray Guns. The
panels are installed on the sides of the Prodigy
Powder Feed Center. The pump panels are
available in four, six, and eight pump
configurations. Each panel houses the Prodigy
HDLV pumps, pump manifolds and pump control
board, air filter and pneumatic controls, and DC
power supply.
This manual provides panel wiring and pneumatic
diagrams and replacement parts only. Refer to the
powder feed center manual for operation
instructions.
Refer to the following manuals for additional repair
and parts information:
1081195 HDLV Pump
1062382 HDLV Pump Manifold and Circuit Board
Figure 1 Prodigy Automatic System HDLV Pump
Panel (Eight-Pump Panel Shown)

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Part 1081748A04 E2010 Nordson Corporation
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 Pumps
2. IN Filtered air supply
(pump assist/pattern air flow)
3. IN Air supply (pinch and vacuum)
4. Pattern air out
5. INPUT power
6. NET/PWR to feed center network
junction box
7. Vacuum exhaust mufflers
8. Purge pilot−bottom bank of
pumps
9. Purge pilot−top bank of
pumps
10. Accumulator tank
11. Purge air tubing/Y-connectors

ProdigyrAutomatic System HDLVrPump Panel 5
Part 1081748A04
E2010 Nordson Corporation
Internal Components
1
2
3
4
5
679
8
10
11
12
Figure 3 Internal Pump Panel Components (Eight-Pump Panel Shown)
1. Pump control manifolds
2. Pump circuit boards
3. Power and network terminal strip
4. Filter
5. Fuses
6. 145 W power supply
7. 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 flow
regulator
11. Pinch select manifold
12. Purge pilot manifold

ProdigyrAutomatic System HDLVrPump Panel
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Part 1081748A04 E2010 Nordson Corporation
Pump Panel Configuration and Layout
The pump panel is available in 4-, 6-, and 8-pump configurations. Up to four pump panels may be
connected to a single powder feed center.
Network Switch Settings
Use the following guidelines to set switches SW1
and SW2 on each HDLV pump circuit board.
SW1 Settings
SW1 identifies the sequential node
address of the circuit board.
Each circuit board controls two pumps. Refer to
the following chart and Figure 5 for a description of
how to set SW1.
Switch
Position
Pumps Controlled
Left Side of
Feed Center
Right Side of
Feed Center
11, 2 17, 18
23, 4 19, 20
35, 6 21, 22
47, 8 23 ,24
59, 10 25, 26
611, 12 27, 28
713, 14 29, 30
815, 16 31, 32
SW2 Settings
See Figure 4. SW2 identifies the pump panel
address 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)
2Down (not used)
3Down (not used)
4Down: Automatic Guns
Up: Manual Guns
123
OPEN
4
Gun Group
= Guns 17−32
= Guns 1−16
1
2
Not Used
3
Gun Type
= Manual
= Automatic
4
Figure 4 SW2 Settings

ProdigyrAutomatic System HDLVrPump Panel 7
Part 1081748A04
E2010 Nordson Corporation
Typical Pump Panel Layout
Figure 5 shows the layout and switch settings of a
typical powder feed center. The example shows a
layout that controls 28 automatic and four manual
powder spray guns.
Pump panel layout typically follows these
guidelines:
SA powder feed center may have up to four
separate pump panels.
SEach pump panel may control up to eight
pumps.
SOne circuit board controls two pumps.
SManual guns are typically connected to the last
pumps in the feed center.
SThe network must be terminated at the last
circuit board in the feed center.
W1
CAN 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
1Network Termination:
Jumper across pins 1 and 2
on 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

ProdigyrAutomatic System HDLVrPump Panel
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Part 1081748A04 E2010 Nordson Corporation
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)

ProdigyrAutomatic System HDLVrPump Panel 9
Part 1081748A04
E2010 Nordson Corporation
Pump Manifolds to Circuit Board
87 654321
(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 BEFORE
MOUNTING BOARDS
SW1
SW2
Figure 7 Pump Panel Pneumatic Diagram −Pump Manifolds to Circuit Board

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Part 1081748A04 E2010 Nordson Corporation
Wiring Diagrams
Circuit Board to Pump Manifolds
SW1
+24VDC
BLACKBLACK
RED
BLUE
BRN
GRN/YEL
BLUE BRN GRN/YEL
+24VDC
BLACK
BLUE BRN GRN/YEL
RED
1
8
1
4321
8
1
J3
PATT B
SOL
1
J4
PUMP B SOL
11
J2
PUMP A
SOL
1
J1
PATT A
SOL
1
P4
J5
P2
PUMP
B
P1
PUMP
A
P5
CAN
OUT
P6
CAN IN
W1
CAN BUS
TERM
11
P3
DC
POWER
GRN/YEL
BRN
BLUE
+24VDC BLUE
GND GRN/YEL
PATTERN BRN
+24VDC BLUE
GND GRN/YEL
FLOW BRN
SOL.7
SOL.1
HDLV PUMP CONTROL MANIFOLD
GND GRN/YEL
FLOW 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.6 SOL.7
SOL.2
SOL.5
SOL.4
SOL.1
SOL.3
SOL.6
2HDLV PUMP CONTROL MANIFOLD 1
TO HDLV PUMP
CONTROL MANIFOLD 2
SOLENOIDS 1 −7
TO HDLV PUMP
CONTROL MANIFOLD 1
SOLENOIDS 1 −7
PRODIGY
DUAL PUMP
CONTROLLER
SW2
Figure 8 Circuit Board to Pump Manifolds Wiring Diagram

ProdigyrAutomatic System HDLVrPump Panel 11
Part 1081748A04
E2010 Nordson Corporation
Network and Power Wiring Diagram
BROWN
BLUE
145W POWER SUPPLY
BLACK
GRAY
ORANGE
RED
SK2
4
5
6
2 3
1
L1 (5)
SK1
L2 (3)
BLACK
1
8 1
4321
8 1
J3
1
J4
11
J2
1
J1
1
P4
J5
P2 P1
P5 P6 W1
11
P3
PINCH 1
PINCH 2
PURGE 1
PURGE 2
RED
RED
BLACK
RED
BLACK
GRAY
BLACK
RED
ORANGE
PINCH SELECT
MANIFOLD
RED
BLACK
RED
BLACK
PURGE PILOT
MANIFOLD
TERMINAL
BLOCK
SW2 SW1
P3
111
W1
P4
1
8
P6
P5
11 1 1
4 123
SW2 SW1
8
11
J3
W1
1
P4 P6P5
11
P3
3214
SW2
P5
P4
1
P6
1
J2P2
1
1 8J3J4
J5
1 1 1
J1
SW1
P1
1
8 1
J4P2
1J5
8 11 1
P3
W1
1
1432
SW2
P1J1J2
1 1
8 1
SW1
RED
BLACK
ORANGE
GRAY
GRAY GRAY
BLACK
RED
ORANGE
BLACK
ORANGE
RED
RED
BLACK
ORANGE
GRAY
RED
GRAY
ORANGE
BLACK
BLACK
RED
22” CUT LENGTH
FUSE HOLDERS 1068938
FUSES 939144
BROWN
BLUE
GRN/YEL
L (L1 −HOT)
N (L2 −NEUTRAL)
BROWN BLUE
BLUE
BROWN
L1L2
GREEN/YEL
FILTER
334805
1
4
52
3
BLUE
BROWN
HARNESS,PUMP
CONTROLLER,FILTER
POWER SUPPLY END VIEW
BOARD 2
BOARD 1
BOARD 3
BOARD 4
SEE SWITCH DETAILS CORRESPONDS WITH BOARD NUMBER
ADJUST VOLTAGE
TO 24.0V 0.1V
GRN/YEL GND (1)
CAN NETWORK IN
(FROM ICONTROL OR PREVIOUS PUMP PANEL)
CAN NETWORK OUT
(TO NEXT PUMP PANEL OR MANUAL GUN INTERFACE)
GRN/YEL
1
1
W1
CAN BUS TERM
JUMPER PINS
2 & 3
TYP. ALL BOARDS
Figure 9 Network and Power Wiring Diagram

ProdigyrAutomatic System HDLVrPump Panel
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Part 1081748A04 E2010 Nordson Corporation
Parts
To order parts, call the Nordson Finishing Customer Support Center at [phone] or contact your local
Nordson representative.
Internal Pump Panel Replacement Parts
See Figure 10.
Item Part Description Quantity Note
1- - - - - - 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 SFUSE, 4amp, slo blow, fast acting, 250 V 2
6 1069113 POWER SUPPLY, 145 Watt 1
7 1077780 REGULATOR ASSEMBLY, 3, Prodigy 1
8 1064135 SREGULATOR, manifold, modular style 3
9 1065536 SGAUGE, air, 0−100 psi, 0.7 bar, 1/8in. RPT 3
10 1033878 REGULATOR, rolling diaphragm, 0−120 psi,
1/2in.-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 switch
settings. 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

ProdigyrAutomatic System HDLVrPump Panel 13
Part 1081748A04
E2010 Nordson Corporation
1
2
3
4, 5
67
10
12
11
8
9
Figure 10 Internal Pump Panel Replacement Parts (Eight-Pump Panel Shown)

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Part 1081748A04 E2010 Nordson Corporation
External Pump Panel Replacement Parts
See Figure 11.
Item Part Description Quantity Note
1 1040664 MUFFLER, male, 1/4-in. BPST AR
2 1081194 PUMP ASSEMBLY, HDLV AR
3 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 Group
Nordson Corporation
Amherst, Ohio, USA
DECLARATION of CONFORMITY
PRODUCT:
Prodigy HDLV Automatic Pump System, 4-8 Applicators
Automatic Pump System for use with Automatic Applicators and Prodigy iControl
APPLICABLE DIRECTIVES:
98/37/EEC (Machinery)
2006/95/EC (Low-Voltage Directive)
2004/108/EEC (Elecromagnetic Compatibility Directive)
87/404/EEC (Simple Pressure Vessel Directive)
STANDARDS USED TO VERIFY COMPLIANCE:
IEC60417 EN61000-6-2 NFPA79
EN12100 EN61000-6-3
EN60204 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 Schroeder
Engineering Manager,
Finishing Product Development Group
Nordson Corporation SWestlake, Ohio DOC14020A03