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Prodigy HDLV Generation II Pump, Pump Manifold, and Circuit Board

Part 1081195-11

2018

Nordson Corporation

Circuit Board Installation

CAUTION:

The circuit board is an electrostatic sensitive device. To prevent damage to the board

while handling it, wear a grounding wrist strap connected to the pump panel or other ground.

Refer to your pump panel manual for the mounting location of the HDLV pump circuit board.

Electrical and Pneumatic Connections

See Figure 21 and refer to the following table for a

description of the appropriate connections on the

circuit board.

NOTE:

Each circuit board may control up to two

pumps. The pump-specific connections on the

circuit board are identified as Pump 1 and Pump 2.

Item

Description

XDCR1

Pump 1 Pattern Air

Pressure Transducer In/Out

XDCR2

Pump 1 Flow Air

Pressure Transducer In/Out

XDCR3

Pump 2 Pattern Air

Pressure Transducer In/Out

XDCR4

Pump 2 Flow Air

Pressure Transducer In/Out

Pump 1 Pattern Air

Flow Control Valve

Pump 1 Pump Air

Flow Control Valve

Pump 2 Pattern Air

Flow Control Valve

Pump 2 Pump Air

Flow Control Valve

JTAG

Programming/Debug Connector

Pump 1 Solenoid I/O Harness

Pump 2 Solenoid I/O Harness

DC Power In

Purge Connector

CAN Out Connector

CAN In Connector

CAN Network Termination Header

Switches and Indicators

See Figure 21 and refer to the following table for a

description of the switches and indicators on the

circuit board.

Item

Description

SW1

Node Address Switch

SW2

Console Address/Gun Type Switch

PB1

Test Mode Switch

(used for calibration)

PB2

Reset Switch

DS1

Power Indicator

DS2

Fault Indicator

P1 and P2 Pinouts

Pin

Function

+24 Vdc

Delivery 2

−

Solenoid 6

Pressure 2

−

Solenoid 5

Suction 2

−

Solenoid 4

Suction 1

−

Solenoid 3

Pressure 1

−

Solenoid 2

Delivery 1

−

Solenoid 1

Vacuum

−

Solenoid 7

Содержание Prodigy HDLV Pump Generation II

Страница 1: ...081195 11 Issued 10 18 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...

Страница 2: ...D System 34 Solenoid and Flow Control Valve Functions 35 Repair 36 Preparation 36 Flow Control Valve Kit Cleaning 36 Flow Control Valve Kit Replacement 38 Solenoid Valve Replacement 38 Manifold Instal...

Страница 3: ...rt number 1098501 to parts list A06 1 10 Replaced solenoid valve 1027412 with part number 1099534 A07 5 10 Replaced manifold assembly 1052915 with part number 1101343 Replaced PCA replacement kit 1057...

Страница 4: ...Change Record ii Part 1081195 11 E 2018 Nordson Corporation...

Страница 5: ...sing incompatible materials S making unauthorized modifications S removing or bypassing safety guards or interlocks S using incompatible or damaged parts S using unapproved auxiliary equipment S opera...

Страница 6: ...he problem has been identified and corrected Grounding inside and around the booth openings must comply with NFPA requirements for Class II Division 1 or 2 Hazardous Locations Refer to NFPA 33 NFPA 70...

Страница 7: ...wder to be purged quickly and thoroughly for fast color changes 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 deliv...

Страница 8: ...and air passages 4 Upper Y Manifold Interface between the pinch valves and the porous tubes consists of two Y shaped passages that join the inlet and outlet branches of either half of the pump 5 Lower...

Страница 9: ...idizing tube s negative air pressure shuts off and the left suction pinch valve closes Right Half Dispensing Powder Out See Figure 3 The right suction pinch valve is closed while the right delivery pi...

Страница 10: ...valves close Pump assist air pressure turns on starting at a low pressure and building up to maximum pump assist pressure The air dispenses powder out of both fluidizing tubes through the powder suct...

Страница 11: ...Air 6 57 l min 0 2 2 0 scfm Total Consumption 85 170 l min 3 6 scfm Operating Air Pressures Pinch Valves 2 4 bar 35 psi Flow Control to pattern air pump assist 5 9 bar 85 psi Vacuum Generator 3 5 bar...

Страница 12: ...ck and tighten it finger tight Flexible 8 mm OD Tubing NOTE The barbed adapters used to connect flexible tubing to the pump are not included with the pump They are shipped with manual powder spray gun...

Страница 13: ...e pinch valve manifold or stress cracks in the pinch valves replace the pinch valves and filter discs Every Six Months or Each Time You Disassemble the Pump Upper Y Manifold Kit 1057262 Lower Manifold...

Страница 14: ...ot opening and closing Defective pinch valve Replace the pinch valves and filter discs Defective pinch solenoid valve Replace the solenoid valve Refer to either the pump panel or control manifold manu...

Страница 15: ...em air pressure before performing the following tasks Failure to relieve air pressure may result in personal injury Relieve air pressure and disconnect the purge air tubing 1 Loosen the fluidizing tub...

Страница 16: ...owder 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 Rem...

Страница 17: ...0 mm tube fittings 2 2 Check valves 2 3 O rings 2 4 Access plugs 2 5 O rings 2 6 O rings 4 7 Fluidizing tubes 2 8 Body gasket 9 Upper Y manifold gasket 10 Upper Y manifold 11 O rings 4 12 Pinch valve...

Страница 18: ...ith food must be thoroughly cleansed prior to their first use However do not clean the porous fluidizing tubes 1 2 Refer to Pinch Valve Replacement on page 16 for specific instructions Top Bottom 3 CA...

Страница 19: ...ghtening when the pinch valve manifold contacts the upper Y manifold Then torque the screws as described below Tighten screws two turns at a time using an alternating pattern until pinch valve manifol...

Страница 20: ...e pinch valve kit when you replace the pinch valves Refer to step 7 of the Pump Assembly procedure Pinch Valve Removal 1 Place the pinch valve manifold in a padded vise 2 Grasp the bottom flange of a...

Страница 21: ...h valve is inside the valve manifold Figure 15 Pulling Pinch Valve into Valve Manifold 4 Continue pulling on the insertion tool until the pinch valve pops through the valve manifold and the tool comes...

Страница 22: ...A 10 S MANIFOLD upper Y HDLV pump 1 A 11 1053292 S O RING silicone 0 219 x 0 406 x 0 094 in 4 C 12 1614272 S MANIFOLD pinch valve HDLV pump 1 C 13 S VALVE pinch HDLV pump 4 A C 14 S BLOCK wear lower...

Страница 23: ...igy HDLV Generation II Pump Pump Manifold and Circuit Board 19 Part 1081195 11 E 2018 Nordson Corporation 1 2 4 5 6 7 8 9 10 3 11 12 13 14 15 18 16 17 19 20 6 21 23 18 19 22 Figure 18 Standard Pump Pa...

Страница 24: ...valves Check Valve Upgrade Kit 1078151 Upgrades older pumps to new design check valves Includes all parts shown Hi Flow Fluidizing Tubes Retrofit Kit 1093596 Converts pump to hi flow Lower Manifold We...

Страница 25: ...ve Regulates the air pressure to the spray gun s nozzle which shapes the powder spray pattern 3 Pump Air Flow Control Valve Regulates the positive air pressure to the fluidizing tubes which dispenses...

Страница 26: ...l other related documentation Pump and Manifold Installation Follow these instructions to install a pump and manifold into an existing pump panel 1 See Figure 20 Make sure that the gaskets on the pump...

Страница 27: ...Prodigy HDLV Generation II Pump Pump Manifold and Circuit Board 23 Part 1081195 11 E 2018 Nordson Corporation This page intentionally left blank...

Страница 28: ...2 Pattern Air Pressure Transducer In Out XDCR4 Pump 2 Flow Air Pressure Transducer In Out J1 Pump 1 Pattern Air Flow Control Valve J2 Pump 1 Pump Air Flow Control Valve J3 Pump 2 Pattern Air Flow Cont...

Страница 29: ...SW1 P2 J4 J3 J2 J1 P3 W1 P6 P5 P4 J5 SW2 PB1 PB2 DS2 DS1 Top View Top View J4 J3 J2 J1 P1 P2 8 7 6 5 4 3 2 1 Pump 1 Manifold Pump 2 Manifold Figure 21 Circuit Board Connections Note The circuit board...

Страница 30: ...AN BUS TERM Jumper Settings for Manual Powder Spray Systems Calibrating the Circuit Board NOTE If you have a two gun system be sure to perform this procedure on both Prodigy Manual Gun Controllers Whe...

Страница 31: ...Pressure G 10 mm Blue Pump Assist Pattern Air Flow Control 5 9 bar 85 psi B 8 mm Clear Powder Delivery to Spray Gun H 6 mm Blue Spray Gun Pattern Air Flow Control out to gun C 8 mm Clear Powder Sucti...

Страница 32: ...ntroller manual for specific instructions Pump operation is controlled by specifying a setpoint from 0 100 which translates to a percent of flow at the gun controller At the pump each setpoint results...

Страница 33: ...ntrol valve Refer to Flow Control Valve Replacement on page 38 for instructions Defective pump check valve Replace the check valves 2 Reduced powder output pinch valves are not opening and closing Def...

Страница 34: ...ay gun adapter Clean the surfaces If the end of the feed tubing is damaged cut the damaged end off with a tube cutter Remove the set screw and inlet adapter from the spray gun Blow the adapter and pow...

Страница 35: ...eed Suction or delivery tubing blocked or kinked Check the tubing Blow out the tubing or replace it as necessary Pump panel regulator pressure incorrect Adjust the regulators in the pump panel to the...

Страница 36: ...el less vacuum on one side of pump than the other proceed to procedure A on page 33 S For low vacuum readings less than 8 in Hg on one side of pump or you feel less vacuum on one side of pump than the...

Страница 37: ...and increase the powder flow 3 Check for proper direction of the check valve A Delivery Check Correct vacuum reading 9 14 in Hg The problem is not in the pump or the control manifold Check for problem...

Страница 38: ...y If powder is visible disassemble the dump valve and replace the pinch valve If no powder is visible proceed to Step 2 2 Disconnect the delivery tubing from the COD manifold outlet and install a new...

Страница 39: ...onding ports on the pump and manifold 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 1 2 3 4 5 6 Figure 28 Solenoid and Flow Control Valve Functions Item Function Item Function 1 Left Side Delivery Pinch Valve 6 Right...

Страница 40: ...ng wrist strap connected to the pump panel or other ground 2 Disconnect the flow control valve and solenoid valve wiring harnesses from the circuit board below the manifold 3 Remove the pump from the...

Страница 41: ...1195 11 E 2018 Nordson Corporation Flow Control Valve Kit Cleaning contd 9 1 2 3 4 5 6 7 8 10 1 12 11 2 Figure 29 Manifold Repair 1 Nut 2 Coil 3 Short screws 2 4 Valve stem 5 Spring 6 Cartridge 7 Valv...

Страница 42: ...alve are in place before installing it on the manifold Manifold Installation Refer to Installation on page 22 for instructions for installing the manifold and pump into the pump panel Circuit Board Re...

Страница 43: ...42 S TUBING polyurethane 6 mm OD x 4 mm ID blue AR 9 1098501 S KIT flow control valve pump control 2 10 1052894 S NIPPLE push in 10 mm tube x 10 mm tube plastic 1 11 328524 S CONNECTOR male with inter...

Страница 44: ...Prodigy HDLV Generation II Pump Pump Manifold and Circuit Board 40 Part 1081195 11 E 2018 Nordson Corporation 1 12 6 5 4 3 2 10 7 8 8 11 14 17 15 15 11 9 16 3 8 15 13 18 Figure 30 Manifold Parts...

Страница 45: ...your system Solenoid Valve Part 1099534 Quantity of 1 Instructions on page 38 Flow control valve kit Part 1098501 Quantity of 1 Instructions on page 38 PCA Replacement Kit This kit comes with the 4 m...

Страница 46: ...Blue polyurethane F 900740 10 mm Blue polyurethane B 173101 8 mm Clear polyethylene G 900740 10 mm Blue polyurethane C 173101 8 mm Clear polyethylene H 900742 6 mm Blue polyurethane D 173101 8 mm Clea...

Страница 47: ...N ISO80079 37 Principles This product has been designed manufactured according to the directives standards norms described above Markings and Certs Flammable Atmosphere Marking Ex h IIIC T40 C Dc Tech...

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