Nordson Prodigy Generation II User manual

ProdigyrGeneration II
High-Capacity
HDLVrPowder Transfer Pump
Customer Product Manual
Part 1092270−05
Issued 2/18
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 1092270−05 E2017 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..................................
High-Capacity HDLV Pump Components 4......
Theory of Operation 6........................
Pumping 6...............................
Purging 7................................
Specifications 8..............................
Installation 9..................................
Pickup Tube Adapter Assembly 10..............
Operation 10...................................
Maintenance 11................................
Troubleshooting 12.............................
Repair 13......................................
Fluidizing Tube Replacement 13................
Pump Disassembly 14.........................
Pump Assembly 16...........................
Pinch Valve Replacement 18...................
Pinch Valve Removal 18....................
Pinch Valve Installation 19...................
Tubing Diagrams 20...........................
Parts 22.......................................
Using the Illustrated Parts List 22...............
Pump Assembly 23...........................
Pump Assembly without Controls 24.............
Pump Controls 26.............................
Left Side 26...............................
Right Side 27..............................
Powder and Air Tubing 29......................
Pickup Tube Adapters 30......................
Adapter with Pump Mount O-Ring 30..........
Adapter without Pump Mount O-Ring 30.......
Spare Parts 31...............................
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 2008. 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, Prodigy, Nordson, and the Nordson logo are registered trademarks
of Nordson Corporation.

Change Record i
Part 1092270−05
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Change Record
Revision Date Change
A02 7/09 Removed 1034396 muffler and replaced with 1097195 muffler. Added
170269 mufflers to miniature valve. Changed all illustrations that mufflers
appear in.
A03 8/09 Added pinch valve kit 1097919 and cleaning instructions.
A04 10/10 Added fluidizing tube kit 1104542 for powders with high proportions of
fines.
05 9/17 Removed Kit 1092272, Other miscellaneous nomenclature and part
number changes.

Change Record
ii
Part 1092270−05 E2017 Nordson Corporation

Prodigy Generation II High-Capacity HDLV Pump 1
Part 1092270−05
E2017 Nordson Corporation
Prodigy Generation II High-Capacity HDLV Pump
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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SObtain and read Material Safety Data Sheets
(SDS) 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
SDS 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.

Prodigy Generation II High-Capacity HDLV Pump 3
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Description
The Prodigy High-Capacity HDLV (High-Density
powder, Low-Volume air) powder pump transports
large amounts of powder from one location to
another.
The pump design and the small diameter suction
and delivery tubing used with the pump allow it to
be purged quickly and thoroughly.
The pump is more efficient than traditional
venturi-style pumps in that very little of the air that
is used to operate the pump is mixed into the
powder stream. Only the air that is used to move
the powder out of the pump and into the delivery
tubing enters the powder stream.
Figure 1 Prodigy High-Capacity HDLV Pump

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High-Capacity HDLV Pump Components
See Figure 2.
Item Description Function
Air Control Components
1Fluidizing Tube Control Valve Cycles to alternate positive and negative air pressure to the
fluidizing tubes.
2Pinch Valve Control Valve Cycles to switch the pinch pressure between the pinch
valves in each pump halves.
3Conveying Air Regulator and
Gauge
Regulates the positive and negative air pressure being
applied to the fluidizing tubes. Typically set to 0.7−1.0 bar
(10−15 psi).
4Exhaust Muffler Allows the pump’s operating air to silently exit the pump.
5Input Air Fitting Connects the high-capacity HDLV pump to a 4.8 bar
(70 psi) air source.
6Pinch Pressure Regulator
and Gauge
Regulates the air pressure being applied to the pinch
valves. Typically set to 2.4−2.75 bar (35−40 psi).
7Vacuum Generator Works on the venturi principle to generate the negative air
pressure required to draw powder into the fluidizing tubes.
8Timing Valve Controls the fluidizing tube control valve and pinch valve
control valve operating sequences.
Pump Assembly Components
9Purge Air Fittings Send line air pressure through the pump assembly during
the purge process.
10 Fluidizing Tubes Porous cylinders that alternately draw powder in when a
vacuum is applied to their exterior, and force powder out
when air pressure is applied to their exterior. The tubes act
as a filter to prevent powder from passing through and
contaminating the control valves and air tubing.
11 Powder Delivery Tube Fitting 16-mm OD polyethylene tube fitting to the powder
destination.
12 Powder Suction Tube Fitting 16-mm OD polyethylene tubing from the powder source.
13 Lower Wear Block Provides a powder path from the suction and delivery
fittings to the pinch valves on both halves of the pump.
14 Pinch Valves Open and close to allow powder to be drawn in or forced
out of the fluidizing tubes.
15 Upper Y-Manifold Interface between the pinch valves and the porous tubes;
consists of two Y-shaped passages that join the pinch
valves to the fluidizing tubes.

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1
2
4
8
5
11
13
14
12
10
15
9
6
7
3
Figure 2 Pump Components (shown with cover removed)

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Theory of Operation
Pumping
See Figure 3. The Prodigy high-capacity HDLV pump consists of two halves that function identically. The
halves alternately draw powder in and force powder out of the pump; while one half is drawing powder in, the
other half is forcing powder out.
Front Half in Suction Phase
The front suction pinch valve is open, and the
front delivery pinch valve is closed. A vacuum is
applied to the front fluidizing tube, which draws
powder through the suction tubing, inlet fitting,
inlet lower wear block, front suction pinch valve,
and into the front fluidizing tube.
After a set period of time, the vacuum is shut off
and the front suction pinch valve closes.
Rear Half in Delivery Phase
The rear suction pinch valve is closed, and the
rear delivery pinch valve is open. Air pressure is
applied to the rear fluidizing tube, forcing the
powder out of the fluidizing tube and through the
rear delivery pinch valve, lower wear block,
delivery fitting, and delivery tubing to the powder
destination.
Next each halves switches to the alternate phase.
The front half now forces out the powder in the
fluidizing tubes while the rear half draws powder in.
Air
Air Air
Powder
Air
Air Air
Powder
Figure 3 Theory of Operation — Pumping

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Purging
NOTE: The pump purge process is dependent on
how the pump is integrated into a powder coating
system.
See Figure 4. The pump must be operating while it
is purged. During the purge, line air pressure flows
through the fluidizing tubes, the pinch valves, and
out the suction and delivery lines.
If the purge air is supplied from a feed center or
bulk delivery system it is typically pulsed. The
pulses are typically 250 milliseconds on and 250
milliseconds off.
If the purge is manually initiated by pressing the
purge button on a manual pump station, the purge
air is not pulsed. The purge button should be
pressed repeatedly to supply air in pulses.
Pulses of
Line Air Pressure
Figure 4 Theory of Operation — Purging

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Specifications
Output (Maximum) 4 kg (9 lb) per minute
Input Air 4.8 bar (70 psi)
Purge Air Line Air Pressure (7 bar (100 psi) maximum)
Operating Air Pressures
Pinch Valves
Conveying Air
2.4−2.75 bar (35−40 psi)
0.7−1.0 bar (10−15 psi)
Air Consumption
Conveying Air
Total Consumption
28−56 l/min (1−2 cfm)
198−255 l/min (7−9 cfm)
Tubing Size
Air Input
Powder Suction
Powder Delivery
8-mm OD polyurethane
16-mm OD polyethylene, 3.65-m (12-ft) long max
16-mm OD polyethylene, 30.5-m (100-ft) long max
NOTE: For best results, keep the powder suction
and delivery tubing as short as possible.
Dimensions See Figure 5.
522.55 mm
(20.57 in.)
160.9 mm
(6.336 in.)
264 mm
(10.4 in.)
Figure 5 Pump Dimensions

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Installation
WARNING: The pump must be securely connected to a true earth ground. Failure to ground the
pump could result in a fire or explosion.
NOTE: The pump is normally mounted on a panel that includes an operating air regulator, and a manual
pushbutton and piloted-operated air valve for manual purging. The panel may also include an auxiliary
regulator for fluidizing the powder source.
From customer-supplied purge air source (7 bar (100 psi) max)
292 mm
(11.497 in.)
200.0 mm
(7.874 in.)
152.0 mm
(5.984 in.)
Panel Mounting Dimensions
Use the supplied M6 screws, washers, and nuts to mount the pump.
NOTE: Five mounting holes and four sets of M6 fasteners are included.
Use the four mounting holes that best match your mounting surface.
5x
7.0 mm
(0.276 in.)
160.0 mm
(6.299 in.)
CONNECTION TYPE FUNCTION
10 mm blue polyurethane tubing
16 mm clear polyethylene tubing
16 mm clear polyethylene tubing
8 mm black polyurethane tubing
Pump ground wire
Delivery: to powder destination
Suction: from powder source
From input air source 4.8 bar (70 psi)
To earth ground
A
B
C
D
Delivery
Maximum
30.5 m (100 ft) Suction
Maximum
3.65 m (12 ft)
B
CD
AA
Tubing Connections
NOTE: For best results, keep the powder
suction and delivery tubing as short as possible.
Figure 6 Pump Installation

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Pickup Tube Adapter Assembly
The pickup tube adapter assembly easily adapts
16-mm suction tubing to a standard pump pickup
tube.
NOTE: Pickup tube adapter assemblies are
available for pickup tubes with or without an
external O-ring. Figure 7 shows a pickup tube with
an external O-ring.
1. See Figure 7. Cut the end of the suction
tubing (1) square with a tubing cutter.
2. Insert approximately 2 inches of the suction
tubing through the retaining nut (2).
3. Install the O-ring (3) onto the suction tubing.
4. Insert the suction tubing into the pump
adapter (4) until it bottoms out.
5. Slide the O-ring down the suction tubing until it
bottoms out against the pump adapter.
6. Tighten the retaining nut onto the pump
adapter.
7. Install the adapter assembly onto the pickup
tube (5) using a twisting motion.
1
2
3
4
5
Figure 7 Pickup Tube Adapter Assembly
Operation
See Figure 8. After making the initial pump assist
and pinch air pressure settings, you should not
have to adjust them again.
STo start the pump, turn on the operating air
supply. Regulate the air pressure to 4.8-bar
(70-psi).
STo stop the pump, turn off the operating air
supply.
Operating the pump at the recommended 4.8-bar
(70-psi) pressure produces an approximately
500-millisecond cycle rate.
SIncreasing the pressure slows down the pump.
SDecreasing the pressure speeds up the pump.
Input Air
4.8 bar
(70 psi)
Conveying Air
Pressure
0.7−1.0 bar
(10−15 psi) Pinch Pressure
2.4−2.75 bar
(35−40 psi)
Powder
Delivery Powder
Suction
Figure 8 Pump Operation

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Maintenance
Perform these maintenance procedures to keep your pump operating at peak efficiency.
WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety
instructions in this document and all other related documentation.
NOTE: You may have to perform these procedures more or less frequently, depending on factors such as
operator experience and type of powder used.
Frequency Part Procedure
Daily
Pinch
Valves
Kit
1092273
Inspect the pinch valve body for signs
of powder leakage. If you see powder
in the pinch valve body or stress cracks
in the pinch valves, replace the pinch
valves.
Every Six Months
or
Each Time You
Disassemble the
Pump
Upper Y-Manifold
Kit 1057269
Lower Y Body
Part 1053976
Disassemble the pump assembly and
inspect the lower Y body and upper
Y-manifold for signs of wear or impact
fusion. Clean these parts in an
ultrasonic cleaner if necessary.
NOTE: To reduce downtime, keep a
spare upper Y-manifold and lower Y
body in stock to install while you are
cleaning the other set.

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Troubleshooting
Problem Possible Cause Corrective Action
1. Reduced powder
output
(pinch valves are
opening and closing)
Blockage in the powder tubing to
the destination
Check the tubing for blockages.
Purge the pump.
Conveying air is set too high Decrease the conveying air pressure.
Conveying air is set too low Increase the conveying air pressure.
Defective pinch valve Replace the pinch valves.
Fluidizing tubes clogged Replace the fluidizing tubes.
Conveying air solenoid valve not
actuating
Refer to the Tubing Diagrams on
pages 20 and and 21. Turn off the
pump and disconnect tubes J and K
from the top of the pump. Turn the
pump on and check the tubes for
alternating positive and negative air
pressure. If there is no pressure,
replace the valve.
If the valve is actuating, but you
cannot feel positive or negative air
pressure at the tubes, check for
obstructions in the air lines leading in
and out of the valve.
Timing valve not actuating Replace the timing valve.
2. Reduced powder
output
(pinch valves are not
opening and closing)
Defective pinch valve Replace the pinch valves.
Defective check valve Replace the check valves.
Pinch pressure solenoid valve not
actuating
Refer to the Tubing Diagrams on
pages 20 and and 21. Turn off the
pump and disconnect tubes H and G
from the pump. Turn the pump on
and check the tubes for alternating
positive air pressure. If there is no
pressure, replace the valve.
If the valve is actuating, but you
cannot feel air pressure at the tubes,
check for obstructions in the air lines
leading in and out of the valve.
Timing valve not actuating Replace the timing valve.
3. Reduced powder
input (loss of suction
from powder source)
Blockage in the powder tubing
from the feed source
Check the tubing for blockages.
Purge the pump.
Loss of vacuum at the vacuum
generator
Check the vacuum generator for
contamination.
Check the exhaust muffler. If the
exhaust muffler appears to be
plugged, replace it.
Damaged O-rings in powder path Check all powder path O-rings.
Replace any worn or damaged
O-rings.
4. Pinch valves failing
rapidly, cracking
around the flange
Powder is tribo-charging in the
pump and grounding through the
pinch valves
Replace the standard blue pinch
valves with black non-conductive
pinch valves. Refer to Parts for the
non-conductive pinch valve kit.

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Repair
WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety
instructions in this document and all other related documentation.
WARNING: Shut off and relieve system air pressure before performing the following tasks.
Failure to relieve air pressure may result in personal injury.
Fluidizing Tube Replacement
NOTE: Four O-rings are included in the fluidizing tube kit. Replace the O-rings if they are worn. It is not
necessary to replace the O-rings each time you replace the fluidizing tubes.
Shut off and relieve purge
air pressure.
Disconnect the purge air
tubing.
1
3
Look down into the pump to make sure the O-rings
are seated in the upper-Y manifold. If they are not
seated, use the fluidizing tubes to seat them.
Check the O-rings in the inside
diameter of the access plugs.
Replace them if necessary.
Remove the fluidizing
tube access plugs
Pull the fluidizing tubes
straight out of the pump.
2
Tighten the
fluidizing tube
access plugs
and connect
the purge air
tubing.
4
Insert the fluidizing
tubes straight into
the pump.

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Pump Disassembly
WARNING: Shut off and relieve system
air pressure before performing the
following tasks. Failure to relieve air
pressure may result in personal injury.
NOTE: Tag all air and powder tubing before
disconnecting from the pump.
1. See Figure 9. Disconnect the purge air lines
from the top of the pump.
2. Disconnect the inlet and outlet powder tubing
from the bottom of the pump.
3. Remove the two screws (A) and the cover from
the pump.
4. See Figure 10. Disconnect one end of each of
the seven air tubes indicated.
NOTE: The letters in Figure 10 correspond to
the letters in the Tubing Diagram on page 20.
5. See Figure 9. Remove the two screws (B)
securing the pump assembly to the base.
Remove the pump assembly to a clean work
surface.
6. See Figure 11. Starting with the fluidizing
tubes, disassemble the pump as shown.
NOTE: Refer to Pinch Valve Replacement on
page 18 for pinch valve replacement instructions.
Filter discs are included in pinch valve kits.
A
A
B
Figure 9 Removing the Pump Assembly
JK
A
G
H
B
U
Figure 10 Disconnecting Air Tubing

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1
2
3
19
18
17
5
4
4
8
6
7
15
9
10
11
12
14
13
16
17
Figure 11 Pump Disassembly and Assembly
1. 10-mm tube connectors (2)
2. Check valves (2)
3. Fluidizing tube access plugs (2)
4. 6-mm tube connectors (4)
5. Outer fluidizing tube assembly
6. O-rings (2), 0.625 x 0.813 in.
7. Filter discs (2)
8. Fluidizing tubes (2)
9. Upper-Y manifold
10. Pinch valves (4)
11. Pinch valve body
12. Lower-Y body
13. 120-mm screws (4)
14. 16-mm tube connectors (2)
15. O-rings (2), 0.219 x 0.406 in.
16. O-rings (2), 1.188 x 1.375 in.
17. O-rings (4), 0.688 x 0.875 in.
18. O-rings (2), 1.25 x 1.063 in.
19. O-rings (2), 0.438 x 0.625 in.

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Pump Assembly
CAUTION: Follow the assembly order and specifications shown. Pump damage may occur if you
do not carefully follow the assembly instructions.
NOTE: Upper and lower Y manifolds intended for repeated contact with food must be thoroughly cleansed
prior to first use. However, do not clean the porous fluidizing tubes.
CAUTION: Do not over-
tighten the fittings. You
will strip the threads.
1
12
14
2Refer to Pinch Valve
Replacement on
page 18 for specific
instructions.
11
10
315
11
4
9
16
7
6
17
5
1
23
4
Tighten screws two
turns at a time to
7−10 in. lb using an
alternating pattern.
5
12
11
9
13