prodigy color-on-demand system generation iii - 1102101prodigy color-on-demand system generation iii...

Prodigy� Color-on-Demand�System Generation III

Customer Product ManualPart 1102101-07

Issued 8/18

NORDSON CORPORATION AMHERST, OHIO USA

For parts and technical support, call the Industrial CoatingSystems Customer Support Center at (800) 433-9319 or

contact your local Nordson representative.

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

Part 1102101-07 � 2018 Nordson Corporation

tents

Table of ContentsSafety 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Components 3. . . . . . . . . . . . . . . . . . . . . . .Pump Control Panel 4. . . . . . . . . . . . . . . . . . . . . . . .

Manifold Specifications 4. . . . . . . . . . . . . . . . . . .Panel Components 5. . . . . . . . . . . . . . . . . . . . . .HDLV Pump Manifold Components 6. . . . . . . .

Color-on−Demand Controller and Panel 7. . . . . . . .Accumulator Tank Function 7. . . . . . . . . . . . . . .Color Change Manifold 7. . . . . . . . . . . . . . . . . . .

System Installation 9. . . . . . . . . . . . . . . . . . . . . . . . . .Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Pump Stand Installation 9. . . . . . . . . . . . . .Controller Installation 10. . . . . . . . . . . . . . . . . . . . . . .

Pump Stand Mounting 10. . . . . . . . . . . . . . . . . . . .Wall or Panel Mounting 10. . . . . . . . . . . . . . . . . . .Rail Mounting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .Grounding 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection Diagram (Rear View of System) 11. . .System Power, Ground, and Gun Controller Connections 12. . . . . . . . . . . . . . . . .System Air Supply and Gun Air Connections 13. . .Color-on-Demand Controller and Foot Switch Connections 14. . . . . . . . . . . . . . . . . . . .Ethernet Cable Termination 15. . . . . . . . . . . . . . . . . .Delivery Tubing Installation 18. . . . . . . . . . . . . . . . . .Suction and Dump Tubing Installation 19. . . . . . . . .Remote Color Selection and Color Change Start Option 20. . . . . . . . . . . . . . . . . .

Pump Control Panel Setup and Operation 21. . . . .Manifold and Pump Installation 21. . . . . . . . . . . . . . .Pump Control Board 22. . . . . . . . . . . . . . . . . . . . . . . .

Electrical and Pneumatic Connections 22. . . . . .Switches and Indicators 22. . . . . . . . . . . . . . . . . .P1 and P2 Pinouts 22. . . . . . . . . . . . . . . . . . . . . . .Control Board Configuration 24. . . . . . . . . . . . . . .Network Termination 24. . . . . . . . . . . . . . . . . . . . .Calibration Procedure 24. . . . . . . . . . . . . . . . . . . .

Air and Powder Tubing Connections 25. . . . . . . . . .Operation 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Color-on-Demand Controller Setup and Operation 27. . . . . . . . . . . . . . . . . . . . . . . . .

Screen Map 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Color Change without Suction Line Purge 28. . . . .Button Labeling 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .System Cleaning 29. . . . . . . . . . . . . . . . . . . . . . . . . . .Color Change with Suction Line Purge 30. . . . . . . .Valve Counters 30. . . . . . . . . . . . . . . . . . . . . . . . . . . .System Clock 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Software Version 31. . . . . . . . . . . . . . . . . . . . . . . . . . .

Screen Brightness 31. . . . . . . . . . . . . . . . . . . . . . .Troubleshooting 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Control Panel 32. . . . . . . . . . . . . . . . . . . . . . . .Solenoid and Flow Control Valve Functions 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Color-on-Demand Controller and Control Panel 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inputs 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Outputs 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Powder Flow 36. . . . . . . . . . . . . . . . . . . . . . . . . . . .Service Screen 37. . . . . . . . . . . . . . . . . . . . . . . . . .

Repair 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump Control Panel Repair 38. . . . . . . . . . . . . . . . . .

Preparation 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flow Control Valve Cleaning 38. . . . . . . . . . . . . .Flow Control Valve Replacement 39. . . . . . . . . .Solenoid Valve Replacement 39. . . . . . . . . . . . . .Manifold Installation 39. . . . . . . . . . . . . . . . . . . . . .

Color-on-Demand Controller and Control Panel Repair 40. . . . . . . . . . . . . . . . . . . . . . .

Manifold Repair 40. . . . . . . . . . . . . . . . . . . . . . . . .Dump Valve Repair 42. . . . . . . . . . . . . . . . . . . . . .

Parts 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Manuals 43. . . . . . . . . . . . . . . . . . . . . . . . . . .Single Gun System 43. . . . . . . . . . . . . . . . . . . . . . . . .Dual Gun System 43. . . . . . . . . . . . . . . . . . . . . . . . . .Pump Panel Replacement Parts 44. . . . . . . . . . . . . .

Manifold Air and Powder Tubing Part Numbers 46. . . . . . . . . . . . . . . . . . . . . . . . . . .

Color-on-Demand Contoller and Control Panel Parts 47. . . . . . . . . . . . . . . . . . . . . . . . .

Controller Kit Parts 47. . . . . . . . . . . . . . . . . . . . . . .Controller Parts 48. . . . . . . . . . . . . . . . . . . . . . . . .Color Change Control Panel Parts 50. . . . . . . . .Control Unit (PLC) Parts 52. . . . . . . . . . . . . . . . . .Ship-With Kit Parts 54. . . . . . . . . . . . . . . . . . . . . . .Color Change Manifold Parts 54. . . . . . . . . . . . . .Dump Valve Parts 56. . . . . . . . . . . . . . . . . . . . . . .

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 2010. 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

Color-on-Demand, HDLV, Prodigy, Nordson, and the Nordson logo areregistered trademarks of Nordson Corporation.

Change Record i

Part 1102101-07� 2018 Nordson Corporation

Change RecordRevision Date Change

A 05/10 Combines manuals for the Color-on-Demand System (1084829), PumpControl Panel (1081747), Controller and Panel (1066483), Manifold andDump Valve (1066484)

Updated parts lists, procedures, and diagrams

A02 05/11 Updated Figure 59−Color Change System Wiring Diagram (Dual Unit,Sheet 1 of 2) on Detail B Field Installation

03 5/12 Removed accumulator tank from illustrations and text

04 5/13 Added default number of suction line pulses and pulse range to page 30,Color Change with Suction Line Purge

05 3/18 Obsoleted three part numbers

06 5/18 Added power supply cover kit to part list

07 8/18 Added repair kit

Change Recordii


Prodigy� Color-on-Demand� System Generation III 1


Prodigy� Color-on-Demand� System Generation III

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� Color-on-Demand� System Generation III2


� Obtain and read Safety Data Sheets (SDS) forall materials used. Follow the manufacturer’sinstructions for safe handling and use ofmaterials, and use recommended personalprotection 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 materialSDS 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 faulty electrostaticequipment is hazardous and can causeelectrocution, fire, or explosion. Makeresistance checks part of your periodicmaintenance program. If you receive evena slight electrical shock or notice staticsparking or arcing, shut down all electricalor electrostatic equipment immediately. Donot restart the equipment until the problemhas been 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 aMalfunction 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

System Components The Prodigy Color-on-Demand system has beencarefully tested, inspected, and packaged prior toshipping. Upon receipt, inspect the shippingmaterials and components for visible damage.Report any visible damage immediately to theshipper and to your Nordson representative.

The Prodigy Color-on-Demand System consists ofthe components shown in Figure 1.

The system pump stand is shipped bolted to apallet. The spray guns, controllers, and installationkits are shipped on another pallet.

Prodigy Manual Spray Gun Prodigy Manual Gun Controller(1 per Gun)

Color-on-Demand Controller(1 per Gun)

Color Change Panel(One per System)

HDLV Pump(1 per Gun)

Pump Panel(One per System)

Color ChangeManifolds

(3 per Gun)

Dump Valve(1 per Gun)

System Pump Stand(Front)

System Pump Stand(Rear, w/Cover Removed)

Figure 1 System Components



Pump Control Panel The pump panel is the central electrical andpneumatic enclosure for the Color-on-Demandsystem. The pump panel houses the ProdigyHDLV� pumps, pump manifolds and controlboards, air filter and pneumatic controls, and DCpower supply.

WARNING: Allow only qualified personnelto service this panel. Shut off power at anexternal disconnect before performing anyrepairs. Shut off the air supply at the ballvalve and relieve the system air pressurebefore disconnecting pneumatic tubing orcomponents.

Manifold Specifications

Output (Maximum) 23.5 kg (52 lb)per hour

Air Consumption

Conveying Air 21−35 l/min(0.75−1.25 scfm)

Gun Pattern Air 6−57 l/min(0.2−2.0 scfm)

Total Consumption 85−170 l/min(3−6 scfm)

Operating Air Pressures

Pinch Valves 2.4−2.75 bar(35−40 psi)

Flow Control(to air cap/pump assist) 5.9 bar (85 psi)

Vacuum Generator 3.5 bar (50 psi)

PumpControlPanel

Color-on-DemandColor Control

Panel

HDLVPump 1

HDLVPump 2

Figure 2 Manual Color-on-Demand System Panels



Pump Control Panel Components

20 1

16

15

14

13

1210 8

6

4

9

5

7

11

21

11

17

19

18

2

3

Figure 3 Pump Panel Components (Two-Gun System Panel Shown)

1. Pump 2 purge valve2. Pump 1 control manifold3. Pump 14. 24 VDC power supply5. Line filter6. Power switch and contact block7. Fuse, time delay, 3.15 A

8. Purge pilot manifold/solenoids9. Pump control boards

10. Pinch select manifold/solenoids11. Vacuum generator mufflers12. Air filter13. Pinch low air (35 psi)14. Pinch high air (75 psi)

15. Flow control air (85 psi)16. Vacuum air (50 psi)17. Purge air (85 psi)18. Pump 219. Pump 2 control manifold20. Pump 1 purge valve21. Air supply ball valve

NOTE: One pump control board (9) controls onepump. If the system has two pumps, then there aretwo control boards are stacked on top of eachother.

For wiring and pneumatic diagrams, refer to thefoldouts in the back of this manual.

For pump repair and parts, refer to manual1081195.



HDLV Pump Manifold Components The Prodigy High-Density powder, Low-Volume air (HDLV) powder feed pump transports precise amounts ofpowder from a feed source to a powder spray gun. The pump manifold controls the pump air and vacuumflow. The pump control board controls all manifold functions.

Table 1 Manifold Components

Item Description Function

1 Solenoid Valves Control the air flow to the pump during operation.

NOTE: Refer to Solenoid and Control Valve Functions onpage 33 to identify each valve’s specific function.

2 Pattern Air Flow ControlValve

Regulates the air pressure to the spray gun’s nozzle, whichshapes the powder spray pattern.

3 Pump Air Flow Control Valve Regulates the positive air pressure to the fluidizing tubes,which dispenses the powder out of the tubes.

4 Vacuum Air Solenoid Turns the airflow through the vacuum generator on or off.

5 Vacuum Generator Works on the venturi principle to generate the negative airpressure required to draw powder into the fluidizing tubes.

2 3

4

5

1

Figure 4 Pump Manifold Components



Color-on−Demand Color ControlPanelSee Figure 5. Air and power are supplied to thecolor control panel from the pump control panel.

AGun

Gun B

ManifoldPurgeValves

PLC

FootpedalPressure

Switch

SolenoidValves

SystemPressure

Switch

PumpControlBoards

Figure 5 System Control Panels (Dual Gun System)

The color control panel houses the PLC andsolenoid valves that control the color changesystem. The PLC also interfaces with the pumpcontrol boards in the pump control panel to signal acolor change start.

The Color-on-Demand controller provides theoperator interface for the color change controls.The controller communicates with the color controlpanel through an Ethernet cable.

Power is supplied to the COD controller from thecolor control panel through a separate power cable.

Other major components of the color control panelinclude the manifold purge valves, which providemanifold purge air during the color change cycle;and the system pressure switch, which sensessystem air pressure and prevents a color changefrom starting if the air pressure drops below 70 psi,and the foot pedal pressure switches. When theoperator steps on the foot pedal it sends a signal tothe pressure switch, which signals the PLC toinitiate a color change.

Color Change Manifold

See Figure 6. The color change manifold consistsof 3 valve blocks with 10 ports in the side of eachblock and ports at each end. Of the 30 side ports,28 are powder inlet valves and one is a purge airinlet valve. A separate external dump valve isconnected to the top outlet on the top block.

The manifold valve bladders are inflated to closethe side ports and deflated to open them. Thecurrently selected powder flows around the valvebladder and out the suction line to the HDLV pump.During a color change, air is exhausted from theDump 2 valve, allowing them to open so that purgeair can push the remaining powder in the suctionlines and manifold out through the dump lines tothe booth.

Color change cycle settings are made from theManual Gun Controller interface (Tools>Purge).These settings determine the pump soft purge,pulse purge, and new color pre-load timing.

Both gun controllers must be set for the“Gun No: 1” network address. Refer to the ProdigyHDLV Manual System (manual 1102106) for adescription of the color change cycle and settings.



P1A

Color 28Color 26Color 24

Color 22

Color 20

Purge

Color 27Color 25

Color 23Color 21

Color 19


Color 11

Color 9Color 7Color 5Color 3

Color 1


Color 12Color 10


Color 2

Suction Line to Pump

Dump

Dump 2Valve

Manifolds A B

Manifold(End View)

Panel Stand(Rear View, with Cover Removed)

Dump Valve(Side View)

Pinch Bladder

Bladders

Dump Valve

Figure 6 Color Change Manifold and Dump Valve



System Installation WARNING: Allow only qualified personnel to perform the following tasks. Follow the safetyinstructions in this document and all other related documentation.

Specifications Electrical 100−240 V, 50/60 Hz, 275 VA max. 1 PH

Air Input Pressure 6.2−7.6 bar (90−110 psi) maximum

Air Flow Requirements 10 CFM during purge; 4−6 CFM during normal operation, depending onpowder flow and atomizing air settings.

Weight * 125 kg (275 lbs)

Remote Control Input 24 V, 25 mA max

* Weight of stand with control panels, color change manifolds, and cover.

System Pump Stand Installation The System Pump Stand must be located as closeto the powder feed hoppers as possible, since themaximum suction tubing length is 3 meters (9 ft, 9inches) from the manifold inlet ports to the pumpadapters on the feed hoppers.

WARNING: The stand weighs 125 kg (275lbs. Use approved lifting equipment toremove the stand from the shipping palletand move it to its installation location.

Unbolt the stand from the shipping pallet andsecure two nylon lifting straps to the horizontal barat the top of the stand. Secure the straps to theforks of a forklift or a crane hook. Lift the stand offthe pallet and move it to the chosen location.

Bolt the stand securely to the floor with the lag boltsincluded in the installation kits.

Figure 7 Packaged System Pump Stand



Controller Installation Install the Manual Gun Controller andColor-On-Demand Controller on a wall, panel, orplatform rail before making any connections. Bothcontrollers must be accessible to the operator at alltimes.

Both controllers are shipped with the samemounting hardware.

NOTE: Both Gun 1 controller and Gun 2 controllermust be set for the “Gun No: 1” network address.Refer to the Prodigy Manual Spray Gun Controllermanual for more information.

Pump Stand MountingThe panel stand is shipped with a controller supportarm. It can be bolted to the side of the stand withthe included M8 x 30 bolts and washers. Use theU-brackets and M6 fasteners to mount thecontrollers to the arm; color controller above andgun controller below.

Wall or Panel Mounting

Use the U-bracket and 6M fasteners to mount thecontrollers to a wall or panel.

Rail Mounting

Use the Rail Mount hardware to mount thecontrollers to a platform rail. The bracket will fit any2 inch wide rail or bar.

Grounding

Connect the ground strap to the controller groundstud and clamp it to a true earth ground.

Color or Gun Controller

U−Bracket

Lock Knobs

Ground Strap

Arm, Wall, or Panel Mount Holes(7 mm dia, 208 mm center to center)

M10 Bolt andLockwasher

Post

Rail Bracket

M6 Bolts andWashers

M8 Bolts andLocknuts

Post Bracket

M8 Bolt andLocknut

Rail-MountHardware

Friction Spacers

Figure 8 Controller Mounting



Connection Diagram (Rear View of System)

Gun 1 Gun 2

Gun 1Controller

Gun 2Controller

Fluidizing AirRegulator*

Fluidizing Air

PumpAdapters

System Air

* − Customer Supplied

System Power

12 mmDump

Ethernet Ethernet

PowerPower Foot

Switch B

12 mmDump

Dump 2Valve

ColorManifold B

Gun 2

Color Manifold AGun 1

ColorController

Gun 2

ColorControllerGun 1

ColorControl Panel

Color 28

Color 28

8mm Color 1

8 mmColor 1

Power/NetworkCable

Power/NetworkCable

Pattern AirPatternAir

Delivery TubingDelivery Tubing

GunCable

GunCable

PowderHopper*

8 mm Suction Tubing

FootSwitch A

System Ground

Dump 2Valve

Pump Panel

Pump 1 Pump 2

Figure 9 System Diagram



System Power, Ground, and Gun Controller Connections

Manual Gun Controller #2 Manual Gun Controller #1

Pump Panel(Bottom View)

INPUT POWER100−240 VAC 50/60 Hz 1 275 VA MAX

15 Amp Breaker Max

15 m (50 ft)Network/Power Cable

6 m (20 ft)Gun Cable

15 m (50 ft)Network/Power Cable

6 m (20 ft)Gun Cable

Brown: L1 (hot)

Blue: L2 (neutral)

Green/Yellow: GND

NET/PWR

NET/PWR

1

System Ground

Ground to Booth Base

Ground to Booth Base

NET/PWR

NET/PWR

2

GUN

Optional Gun Cable Extensions4 meter: 10730276 meter: 1083912

GUN

Figure 10 System Power, Ground, and Gun Controller Connections



System Air Supply and Gun Air Connections

Manual Gun #2

Pump Panel

6-mm OD Blue Air Tubing

Manual Gun #1

6-mm OD Blue Air Tubing

Air Supply6.2−7.6 bar (90−110 psi)(12-mm Tubing x 1/2-in. NPT fitting provided)

12

Figure 11 System Air Supply and Gun Air Connections



Color-on-Demand Controller and Foot Switch Connections 1. Connect the power cables to the

Color-on-Demand controllers.

2. Cut one of the RJ45 jacks off the 100 ft. longEthernet cable included in the ship-with kit,leaving a jack on the other end.

3. Remove the back from the controller and plugthe Ethernet cable into the socket as shown.

4. Pull the cut end of the cable through theprovided 1/2 in. conduit connector and conduitto the color panel and route it inside the panel.

5. Connect the cable leads to the terminationmodule as shown on page 15.

6. Connect the conduit to the controller and panel.

7. If you are going to use the foot switches,remove the bottom covers and install theprovided connectors. Connect 6-mm tubingfrom the FOOTSWITCH A & B fitting to the INfitting on the switch, and from the OUT fitting tothe SWA RTN or SWB RTN ports on the tubingmanifolds.

Gun 1 (A)Color-on-Demand Controller

Gun 2 (B)Color-on-Demand Controller

1/2 in. FlexibleConduit

Ethernet Cable

Remove Controller BackPlug Ethernet Cable Here

Power Cable

Color ChangeFoot Switch

Gun 1

Color ChangeFoot Switch

Gun 2

6 mm Tube x 1/8 NPTConnectors 6 mm Tube x 1/8 NPT

Connectors

6 mm BlueTubing

SWBRTN

Power Cable

GroundGround

Ethernet Cable TerminationSee Figure 8

Remove footswitch bottom cover to install connectors

Color Panel

A B

SWARTN

IN OUT

6 mm BlueTubing

IN OUT

Ethernet Cable

1/2 in. FlexibleConduit

Figure 12 Color-on-Demand Controller and Foot Switch Connections



Ethernet Cable Termination Follow these steps to complete the ethernet cabletermination.

1. Cut the RJ45 jack from one end of the Ethernetcable.

2. Route the cut end of the Ethernet cable into thecolor panel.

3. Trim back the cable jacket about eight inches.

4. Cut the foil, clear wrapper, and pull string on thecable.

5. Trim back the four twisted pair wires toapproximately 2.25 inches. 2.25 in



6. See Figure 13. Arrange the twisted pair wiresin the module according to the T568-B wiringscheme, with the ends at least 1/4 in. throughthe terminals. Retain the twists in the wires asclose to the terminals as possible. Use a 110punch-down tool to attach the wires.

7. Trim the ends of the wires as close to thetermination module as possible.

8. Install the retention caps on the terminationmodule.

9. Crimp a ground lug to the shield wire.

10. Assemble the ethernet termination case asshown. For rear-connect modules, snap thetermination module into the bezel, then installthe bezel into the adapter.

Use Type T568B cables.Use T568-B wiring scheme.

White/Blue

Blue

White/Green

Green

White/Orange

Orange

White/Brown

Brown

Rear-Connect Module

Bezel

Module

Bezel

Adapter

Cover

1 /4

in. m

in.

(End View)

Shield

Retention Cap

Shield

Figure 13 Ethernet Cable Connection to TerminationModule



11. See Figure 14. Install the termination modulesunder the top side of the enclosure.

12. Connect the 1 meter (3 ft.) long crossovercables from the termination modules to thePLCs.

13. Attach the termination module ground wires tothe cabinet ground stud.

A

B

AB

Crossover Cables (3 ft)

Ethernet Cable A

Ethernet Cable B

Termination Modules

CabinetGround

Figure 14 Ethernet Cable Termination Inside ColorControl Panel



Delivery Tubing Installation Connect 8-mm clear delivery tubing from the pump outlets to the spray guns. Observe tubing lengthguidelines, coil excess tubing in loops of at least 1 meter (3 ft) diameter, and lay coil flat on floor.

Manual Gun #2

Pump Panel(Bottom View)

Manual Gun #1

Factory InstalledSuction Tubing

Color ChangeManifolds

(Bottom View)

Factory InstalledSuction Tubing

Use Tubing CutterTo Cut Tube Ends SquareBefore Installing

Lock Knob

O-rIng

BarbedTubingAdapter

O-ring

Lock Nut

Tubing Adapter1078006

1 m (3 ft)Minimum Loop

Diameter

Flexible 6 x 8 mm Delivery Tubing:9 m (30 ft) min23 m (75 ft) maxRecommended 20 m (65.5 ft)Coil Excess Tubing And Lay Flat

Figure 15 Delivery Tubing Installation



Suction and Dump Tubing Installation

8-mm OD Clear Tubing3 m (9 ft, 9 in.) maximum

Color 1 Powder Feed Hopper(Not included with system)

Color 28

12 mm Dump Tubing(Route to Booth)

Color 26

Color 24

Color 22

Color 20

Color 18

Color 16

Color 14

Color 12

Color 10

Color 8

Color 6

Color 4

Color 2

Color 27

Color 25

Color 23

Color 21

Color 19

Color 17

Color 15

Color 13

Color 11

Color 9

Color 7Color 5

Color 3

Color 1

P1 Purge Air (Factory Installed)

Color ChangeManifold

Color 2 Powder Feed Hopper(Not included with system)

Vent Hoppersinto Booth

Vent Hoppersinto Booth

8-mm OD Clear Tubing3 m (9 ft, 9 in.) maximum

8-mmTubing

O-ring Lock Knob

Standard 8-mm Poly Tubing

1078007Adapter

Lock Knob

8-mmFlexibleTubing

Flexible 8-mm Tubing

Optional 1078006 Adapterfor Flexible Tubing

Pickup TubeAdapters

Optional 1078006 Adapterfor Flexible Tubing

Figure 16 Suction and Dump Tubing Installation



Remote Color Selection and Color Change Start Option

C24AEC18AE C20AE C22AEMD5A

D1AE

D2AE

C8AE

C7AE

C16AE

C15AE

C23AE

PLC A

C2AE

MD8A

MD7A

SPARE6A

SPARE5A

C1AE

MD6AC10AE

C9AE

C17AE

C4AE C6AE

SPARE1A

SPARE2A

C5AE

SPARE3A

SPARE4A

C3AE

C14AE

C13AE

C21AE

C12AE

C11AE

C19AE

SCCA

RM1A

RS2A

BIT5A

SW1A

RS1A

MD3A

MD4AC26AE

C25AE

SPARE4A

MD2ASPARE2A

SPARE3A

SPARE1A

CCDA

P2AE

BIT3A

C28AE

C27AE

BIT1A

BIT4A

CCSA

CVBADOCA

BIT2A

PS1A

I/OMD1A

USR TXDRXDERROR LINK ON

Bits 1−5: Binary color seclection, colors 1−28Bit 1 = Least Significant BitBit 5=Most Significant Bit

RS2: Remote Start signal

24 V, 25 mA, sourcing (high true)

Set the color selection bits first, then strobe the Remote Start bit.

Gun 1

Gun 2

Dual Control Unit

Figure 17 Remote Color Selection and Color Change Start Connections



Pump Control Panel Setupand Operation

Manifold and Pump Installation To install a pump and manifold into an existingpump panel:

1. See Figure 18. Make sure that the gaskets onthe pump (2) and manifold (5) are notdamaged. If the gaskets are damaged, replacethem.

2. Set the manifold onto the appropriate mountingbracket (4) against the pump panel wall (3).Secure the manifold with the mountingscrews (6), but do not tighten the screws.

3. Secure the pump to the pump panel andmanifold using the pump mounting screws (1).Tighten the pump mounting screws securely.

4. Tighten the manifold mounting screws securely.

5. Perform the Calibration procedure on page 24.

1

3

6

5

4

2

Figure 18 Pump and Manifold Installation

1. Mounting screws (2)2. Pump

3. Pump panel wall4. Manifold mounting bracket

5. Manifold6. Manifold mounting screws (2)



Pump Control Board

CAUTION: The circuit board is an electrostatic sensitive device. To prevent damage to the boardwhile handling it, wear a grounding wrist strap connected to the pump panel or other ground.

Electrical and Pneumatic Connections

See Figure 19 and the following table for thecontrol board connections. Refer to the circuitdrawings in the back of this manual.

Item Description

XD CR1 Gun Pattern AirPressure Transducer In/Out

XD CR2 Pump Flow AirPressure Transducer In/Out

XD CR 3 Not Used

XD CR4 Not Used

J1 Gun Pattern AirFlow Control Valve

J2 Pump AirFlow Control Valve

J3 To Color Control Panel PLC:Dump Output Control (DOC)

J4 To Color Control Panel PLC:Color Valve Back purge (CVB)

J5 JTAG Programming/Debug

P1 Manifold Solenoid I/O Harness

P2 To Color Control Panel PLC:Color Change Status (CCS)

P3 DC Power In

P4 To Color Control Panel PLC:Start Color Change (SCC)Color Change Status (CSS)returnP1E (Purge 1 Solenoid)

To Pump Control Panel:Purge Pilot ManifoldPinch Select Manifold

P5 CAN Out Connector

P6 CAN In Connector

W1 CAN Network TerminationHeader

Switches and Indicators See Figure 19 and the following table for theswitches and indicators on the control board.

Item Description

SW1 Node Address Switch

SW2 Console Address/Gun TypeSwitch

PB1 Test Mode Switch(used for calibration)

PB2 Reset Switch

DS1 Power Indicator

DS2 Fault Indicator

P1 and P2 Pinouts Pin P1 Function P2 Function

1 +24 Vdc Not Used

2 +24 Vdc Not Used

3 +24 Vdc Not Used

4 +24 Vdc Not Used

5 +24 Vdc Not Used

6 +24 Vdc Not Used

7 +24 Vdc Not Used

8 Delivery 2 −Solenoid 6

Not Used

9 Pressure 2 −Solenoid 5

Not Used

10 Suction 2 −Solenoid 4

Not Used

11 Suction 1 −Solenoid 3

Not Used

12 Pressure 1 −Solenoid 2

Not Used

13 Delivery 1 −Solenoid 1

Pull up resistor forCCS

14 Vacuum −Solenoid 7

Color ChangeStatus (CCS)



Bottom View

Top ViewPump 1 Manifold

P1

J2

J1

P2 J4 J3 J2 J1 P1

1 2

3 4

1234

XDCR2 XDCR1

J5

P4

P5 P6 W1

P3

PB1 PB2

SW1

SW2DS1

DS2

Figure 19 Control Board and Manifold Connections

Note: The control board is shipped with air tubing labeled from 4−1 installed in the XDCR fittings. Connect the tubing tothe appropriate fittings on the manifolds as illustrated.



Control Board Configuration

See Figure 20. Make sure that SW1 and SW2 areset as illustrated for the Color-on-Demand system.

SW1 Position 1

1 2 3

OPEN

4

SW2

1 OPEN2 CLOSED3 OPEN4 CLOSED

1 2 3

OPEN

4SW2

1 OPEN2 OPEN3 OPEN4 CLOSED

For Color-on-Demand System:

For Standard Manual Gun System:

Figure 20 SW1 and SW2 Settings

Network Termination

See Figure 21. The control board is shipped with ajumper across pins 2 and 3 of the CAN BUS TERMterminals. Move the jumper to pins 1 and 2.

1

W1CAN BUS TERM

1

W1CAN BUS TERM

As Shipped Position(for Prodigy Standard 2-GunSystem)

Position for ProdigyColor-on-Demand1 or 2 Gun System

Figure 21 CAN BUS TERM Jumper Settings

Calibration Procedure If you replace a control board or manifold, use thisprocedure to calibrate the system.

1. Turn off the Prodigy Manual Gun Controller.

2. Press and hold the Nordson key, then turn onpower to the Prodigy Manual Gun Controller.The Configuration screen appears.

Figure 22 Configuration Screen

3. Using the arrow keys or rotary dial, point to theCALIBRATION selection. Press the � key.The Calibration screen appears.

Figure 23 Calibration Screen

NOTE: Use the arrow keys or rotary dial to movethe cursor to the appropriate setting, then press the� key to select it. Use the arrow keys or rotary dialto change that value, then press the � key toaccept the new value and select a new setting.

4. Enter the PUMP FLOW and PATTERN FLOWA, B, and C calibration numbers from the stickeron the pump control manifold.



Air and Powder Tubing Connections See Figure 24 for the air and powder tubing connections for the pump and manifold.

NOTE: Only the XDCR1 and XDCR2 transducers on the control board are used for this application.

Item Tubing Function Item Tubing Function

A10 mm Blue From Purge Air Source

(Line Air Pressure)

G10 mm Blue

Pump Assist/Pattern AirFlow Control5.9 bar (85 psi)

B 8 mm Clear Powder Deliveryto Spray Gun

H 6 mm Blue Spray Gun Pattern AirFlow Control (to gun)

C 8 mm ClearPowder Suctionfrom Feed Source

1 − 2

4 mm Clear Pump 1 Pattern AirPressure Transducer

D

8 mm Clear

Pinch Valve AirPressure2.0−2.75 bar (30−40psi)

E 10 mm BlueVacuum Air GeneratorSupply 3.45 bar (50 psi)

3 − 44 mm Clear Pump 1 Flow Air

Pressure TransducerF 10 mm Blue Vacuum Generator Vent

Top of Manifold

Bottom of Manifold

A A

C B

F E

D

43

G

12H

Figure 24 Powder and Air Tubing Connections



Operation

WARNING: Allow only qualified personnelto perform the following tasks. Follow thesafety instructions in this document and allother related documentation.

CAUTION: Do not adjust the regulatorsinside the pump cabinet. The regulatorsare factory set and should not be adjustedwithout guidance from your Nordsonrepresentative.

Powder flow rate and pattern air flow is controlledby the gun controller operator interface settings.Refer to the Operation section of the Prodigy HDLVManual System manual for specific instructions.

The powder flow rate is controlled by specifying asetpoint from 0−100, equivalent to a percent offlow, which corresponds to a predefined pumpcycle rate. Increasing the flow rate settingincreases the cycle rate; decreasing the flow ratesetting decreases the cycle rate.

Spray gun pattern air flow (in either scfm or m3/hr)is regulated by the pattern air flow control valve onthe pump manifold.

The color change cycle, which purges the pump,gun, delivery tubing, and suction lines of powderand loads a new color powder, is controlled by thePurge screen settings on the gun controller.

The color change system is controlled by the colorcontrol panel PLC and solenoid valves, and thepump control boards.

Colors are selected and color changes are initiatedby the operator, using the color controller touchscreen and the foot switch, or by a remote signalfrom a customer process controller.

NOTE: When the fluidizing tubes become cloggedwith powder, the powder delivery rate will decrease.The gun controller will generate a fault to indicatethis condition and notify you that it is time toreplace the fluidizing tubes.



Color-on-DemandController Setup andOperation

Screen Map

Big Buttons 15−28Big Buttons 1−14

Main

Splash Screen

Small Buttons

Setup

Button Labels 1−14

Valve Counters

Test

Outputs 1−20

Outputs 21−40

Inputs 1−16

Software Version

Screen Contrast

Button Labels 15−28

System Clock

Purge

Service Screen*

* Service Screen is for use by Nordson CSRs.

Figure 25 Color-on-Demand Controller Screen Map



Color Change without SuctionLine Purge

When the color controller is turned on, the splashscreen appears.

NOTE: Note that the controller power switch onlyturns on and off the controller. The color changePLC remains powered up until the system powerswitch is turned off.

Figure 26 Splash Screen

Touch the Splash screen to open the Main screen.

Figure 27 Main Screen

Choose the desired button size by touching SmallButtons or Big Buttons.

The Small Buttons screen has all 28 color buttonson one screen:

Figure 28 Small Buttons Screen

The Big Buttons screens have 14 color buttons oneach of two screens:

Figure 29 Big Buttons Screen

To change colors, touch the desired color buttonthen the Start button, or touch the Start button andthen select a color, or press the foot pedal thentouch the desired color button.

After starting a color change with the foot pedal orStart button, you have approximately 11 seconds(with factory default Purge settings) to select a newcolor or the system will load the current color again.

When a new color is selected it becomes the Nextcolor while the color in the system is the Currentcolor.

When the color change cycle is complete and thenew color is loaded, the Current color and Nextcolor will be the same. COMPLETE appears at thebottom of the screen.



Button Labeling From the Main Screen, touch Setup. Use theButton Label screens to enter labels for each colorbutton and for the system.

Figure 30 Setup Screen

The first screen has label buttons for colors 1 to 14,plus the label button for the system name. Thesystem name appears in yellow at the bottom left ofthe color buttons screens.

Touch the More button to go to the button labelscreen for colors 15−28.

To create a label for a color or the system name,touch the label button. A keyboard screenappears. Enter a 6-character label for the color, ora 12-character label for the system.

Figure 31 Button Label Screen (1 of 2)

Touch Main to return to the Main screen.

System Cleaning Before shutting down the system or removing airpressure from the system, you must clean thesystem by performing a system purge. You canalso use this procedure to clean the system if itloses air pressure while operating.

From the Main screen, touch Purge. Touch theClean button, then Start.

The system performs a color change cycle withoutloading a new color. COMPLETE appears at thebottom of the screen when the cycle is complete.

Next time the system is started, you must select acolor and perform a full color change to load thecolor. Figure 32 Purge Screen



Color Change with Suction LinePurge NOTE: To perform this procedure the HopperPurge function must be enabled. See the ServiceScreen section on page 37 to enable and disablethe function.

Remove the suction line to be purged from the feedhopper and place the suction line in a hopper forexcess powder disposal (waste).

From the color selection controller screen, selectthe desired color button, then touch Startw/Suction LN. The default number of suctionpulses is 12. The pulse range is from 1 to 50.

The next screen will offer a reminder to confirm ifthe suction line has been removed from the feedhopper.

Touch the Start button to begin the suction linepurge. The words In Process will flash on screenwhile system is cleaning the suction line.

When the system is done purging the suction linethe screen will revert back to the Main screen withthe word Complete showing at the bottom of thescreen.

Figure 33 Screen display for CURRENT suction linepurge

Valve Counters Use the Valve Counter screen for maintenance.The recommended valve bladder change interval is30,000 cycles. When this count is reached, youshould disassemble the color change manifoldsand install new bladders. Replacing the bladdersbefore they fail will prevent color contamination andexpensive unscheduled downtime.

Note that the WARNING BLADDERMAINTENANCE message will appear at the setcount if enabled from the Service Screen. Refer topage 37 for more information on this screen.

Figure 34 Valve Counter Screen



System Clock See Figure 35. To set the system clock, go to theTest screen, then touch the Set Clock button.

Software Version See Figure 35. Go to the Test screen, then touchSoftware Version. This screen displays softwareversion information. You may be asked for thisinformation if you call for technical support.

Screen Brightness After selecting the Software Version option, touchthe arrow buttons to adjust the brightness of thedisplay screen. Figure 35 Test Screen



Troubleshooting WARNING: Allow only qualified personnel to perform the following tasks. Follow the safetyinstructions in this document and all other related documentation.

Pump Control Panel

Problem Possible Cause Corrective Action

1. Reduced powderoutput(pinch valves areopening and closing)

Blockage in the powder tubing tothe spray gun

Check the tubing for blockages.Purge the pump and spray gun.

Defective pump air flow controlvalve

Clean the pump air flow control valve.Refer to Flow Control Valve Cleaningon page 38 for instructions.

If the problem persists, replace thepump air flow control valve. Refer toFlow Control Valve Replacement onpage 39 for instructions.

Defective pump check valve Replace the check valves.

2. Reduced powderoutput(pinch valves are notopening and closing)

Defective pinch valve Replace the pinch valves and filterdiscs.

Defective solenoid valve Replace the solenoid valve. Refer toSolenoid and Flow Control ValveFunctions on page 33 to determinewhich solenoid valve controls theaffected pinch valve.

Defective pump check valve Replace the check valves.

3. Reduced powderinput (loss of suctionfrom feed source)

Blockage in the powder tubingfrom the feed source

Check the tubing for blockages.Purge the pump and spray gun.

Loss of vacuum at the vacuumgenerator

Check the vacuum generator forcontamination.

Check the pump panel exhaustmuffler. If the exhaust mufflerappears to be plugged, replace it.

Defective pump air flow controlvalve

Clean the pump air flow control valve.Refer to Flow Control Valve Cleaningon page 38 for instructions.

If the problem persists, replace thepump air flow control valve. Refer toFlow Control Valve Replacement onpage 39 for instructions.

4. Spray gun fan patternchanges

Defective pattern air flow controlvalve

Clean the pattern air flow controlvalve. Refer to Flow Control ValveCleaning on page 38 for instructions.

If the problem persists, replace thepattern air flow control valve. Referto Flow Control Valve Replacementon page 39 for instructions.



Solenoid and Flow Control Valve Functions

Figure 36 identifies the solenoid and flow control valve functions and the corresponding ports on the pumpand manifold.

7

89

12 3 4

65

12 3 4 5 6 123456

Figure 36 Solenoid and Flow Control Valve Functions

Item Function Item Function

1 Left Side Delivery Pinch Valve 6 Right Side Delivery Pinch Valve

2 Left Side Fluidizing Tube 7 Vacuum Air (on bottom of manifold)

3 Left Side Suction Pinch Valve 8 Pump Air Flow Control

4 Right Side Suction Pinch Valve 9 Pattern Air Flow Control

5 Right Side Fluidizing Tube



Color-on-Demand Controller and Control Panel SYSTEM PRESSURE ALARM: If this messageappears on the screens, the system pressure hasfallen below 70 psi and color changes cannot bestarted. Check the system compressed air supply.

For other color change system troubleshooting, usethe Output and Input screens along with the colorcontrol panel labels. The PLC LEDs, solenoidvalves, and air tubing are all coded on the labels sothat you can track down any problems. Forexample, when color 1 is selected for gun1, theLEDs for C1AE on both the PLC and solenoidshould light.

Refer also to the diagrams and schematics in theback of this manual.

NOTE: You must turn the Test Mode OFF beforeyou can exit the Test screen.

Figure 37 Test Screen

NOTE: Before triggering any outputs from the testscreens, it is strongly recommended that you do asystem purge. Refer to System Cleaning on page29.

On either of the Output screens, touch the Testbutton to toggle the Test mode ON or OFF, thentouch an output button to turn the device on andoff.



Inputs

This screen shows the status of the input signals.The LEDs on the top two PLC modules (MD2 andMD3), should light when the inputs are on. Module2 handles inputs from the system, while module 3handles a binary 5 bit color selection signal andcolor change start signal from a remote customerdevice.

Figure 38 Inputs 1−16 Screen

InputChannel Code Function

1 SW1 Not Used

2 RS1 Remote Start 1: Signal from foot pedal pressure switch.

3 CCS Color Change Status signal from pump control board.

4 CVB Color Valve Back purge signal from pump control board.

5 PS1 Air pressure switch: prevents color change start if air pressure falls below70 psi.

6 DOC Dump Output Control signal from pump control board.

7, 8 Spares

9 RS2 Remote Start 2: 24V remote start signal from customer device to PLC.

10 BIT 5 Binary 5 bit remote color selection inputs for colors 1 − 28 from customerdevice to PLC:

BIT 1 = Least Significant BitBIT 5 = Most Significant Bit

Set the color selection bits first, then strobe RS2.

11 BIT 4

12 BIT 3

13 BIT 2

14 BIT 1

15, 16 Spares N/A



Outputs Touching the Output screen buttons should light the LEDs on the PLC output modules and on thecorresponding solenoid valves, and send an air signal to the appropriate valve bladder.

Figure 39 Outputs 1−20 Screen Figure 40 Outputs 21−40 Screen

OutputChannel Code Function

1 SCC Start Color Change signal to the pump control boards

2 RM1 Remote Monitor 1

3 CCD Not Used

4 P2E Purge 2 solenoid: Manifold purge air inlet actuation air

5−32 C28E−C1E Color 28 to 1 solenoids

33 D1E Dump 1 solenoid: Manifold dump outlet actuation air

34 D2E Dump 2 solenoid: Dump valve actuation air

35 P1E Purge 1 Solenoid

36−40 SPR1−6 Spares

Powder Flow

Lose Flow of one Color: Check for leaks in the siphon tubing from the manifold to the hopper. Check thetubing connections.

Lose Flow of Multiple Colors or All Colors: Check the tubing between the manifold and the dump valve.Check the pinch valve visible inside the dump valve body. If the pinch valve has failed, powder will be visiblein the body cavity around the pinch valve.



Service Screen The Service screen is used by Nordson CSRs.

Dump Valve Counter Reset: Resets the counter.Can also be done from the Valve Counter screen.

Dump Valve Counter Preset: Allows the counterto be reset if accidentally reset from the ValveCounter screen.

Warning Count Set: When this value is exceededby the valve counter, causes the WARNINGBLADDER MAINTENANCE message to appear

Total Color Change Counter: Number of colorchange cycles initiated. Cannot be reset.

Status Arrows: Enables/Disables color changestatus arrows on operation screens. Default is Off.

Local Start Lockout: Enables/Disables colorchange start from the controller. Typically enabledwhen PLC remote color select and start is used.

Hopper Purge Enable: Enables/Disables optionto purge the hopper suction line during a colorchange.

Suction Line Purge Pulses: Number of pulsesused to purge the suction line.

Figure 41 Service Screen



Repair

Pump Control Panel Repair WARNING: Allow only qualified personnelto perform the following tasks. Follow thesafety instructions in this document and allother related documentation.

To reduce downtime, keep a spare manifold instock to install in place of one being repaired.Refer to Manifold Parts on page 46 for orderinginformation.

Repair of the manifold is limited to

� cleaning or replacing the flow control valves

� replacing the solenoid valves

Field replacement of other parts is not possible,due to the need to calibrate the manifold at thefactory using equipment not available in the field.

Preparation

NOTE: Tag all air tubing and wiring harnessesbefore disconnecting them from the manifold.

1. On the color change controller, go to the Purgescreen, touch CLEAN and START to perform asystem purge.

WARNING: Shut off and lock out systemelectrical power and relieve system airpressure before performing the followingtasks. Failure to relieve air pressure mayresult in personal injury.

2. Shut off system power and air pressure.Relieve the system air pressure.

3. Tag the pump manifold air tubing, thendisconnect the tubing from the manifold.

CAUTION: The circuit board is anelectrostatic sensitive device (ESD). Toprevent damage to the board whilehandling it, wear a grounding wrist strapconnected to the pump panel or otherground.

4. Tag and disconnect the flow control valve andsolenoid valve wiring harnesses from the circuitboard below the manifold.

5. Remove the pump from the pump panel.

6. Remove the two screws securing the manifoldto the mounting bracket. Take the manifoldassembly to a clean work surface.

Flow Control Valve Cleaning

A dirty air supply can cause the flow control valvesto malfunction. Follow these instructions todisassemble and clean the flow control valves.

1. See Figure 42. Remove the nut (1) and coil (2)from the flow control valve.

2. Remove the two long screws (10) to remove theflow control valve from the manifold.

CAUTION: The valve parts are very small.Be careful not to lose any parts. Do notmix the springs from one valve with thosefrom another. The valves are individuallycalibrated with the springs installed.

3. Remove the two short screws (3), then removethe valve stem (4) from the valve body (7).

4. Remove the valve cartridge (6) and spring (5)from the stem.

5. Clean the cartridge seat and seals, and theorifice (9) in the valve body. Use low-pressure,compressed air. Do not use sharp metal toolsto clean the cartridge or valve body.

6. Install the spring and then the cartridge in thestem, with the plastic seat on the end facingout.

7. Make sure the O-rings furnished with the valveare in place on the bottom of the valve body.

8. Secure the valve body to the manifold with thelong screws, making sure the arrow on thevalve body points toward the solenoid valves.

9. Install the coil on the stem, with the coil wiringpointing away from the solenoid valves. Securethe coil with the nut.



Flow Control Valve Replacement If cleaning the flow control valve does not correctthe flow problem, replace the flow control valve.

See Figure 42. Remove the valve by removing thenut (1), coil (2), and long screws (10).

Before installing a new valve, remove the protectivecover from the bottom of the valve body (7). Becareful not to lose the O-rings (8) under the cover.

Solenoid Valve Replacement See Figure 42. To remove the solenoid valves,remove the two screws (11) in the valve body andlift the solenoid valve (12) off the manifold.

Make sure the gasket furnished with the newsolenoid valve are in place before installing it onthe manifold.

Manifold Installation

Refer to Installation on page 21 for instructions forinstalling the manifold and pump into the pumppanel.

9

1

2

3

4

5

6

7

8

10

1

12

11

2

Figure 42 Manifold Repair

1. Nut2. Coil3. Short screws (2)4. Valve stem

5. Spring6. Cartridge7. Valve body8. O-rings (2)

9. Orifice10. Long screws (2)11. Screws (2)12. Solenoid valve



Color-on-Demand Controller and Control Panel Repair

WARNING: Allow only qualified personnel to perform the following tasks. Follow the safetyinstructions in this document and all other related documentation.

WARNING: Before making repairs to any component of the system, disconnect and lockout powerat the system disconnect. Shut off the system air supply at the ball valve on the pump panel andrelieve the system air pressure.

Repair of the Color-on-Demand controller and color control panel is limited to replacement of components.Refer to to the foldouts in the back for pneumatic and electrical diagrams.

Manifold Repair The color change manifold consists of threeidentical valve modules connected together withtubing and mounted on a V-shaped panel.

Repair of the manifold modules consists ofdisassembly, cleaning, and reassembly. Thefollowing kits are available for repair:

� Bladder Kit: 10 valve bladders and filter discs

� O-ring Kit: 12 O-rings for tubing connections

Repair Procedure

See Figure 43.

1. Disconnect the air tubing from the elbowfittings (1).

2. Unscrew the side lock knobs (8) and pull thepowder tubing out of the ports.

3. Unscrew the top and bottom lock knobs.

4. Remove the fasteners securing the modulebracket to the panel. Save the fasteners forreuse.

5. Lift the module away from the panel and moveit to a clean workbench.

6. Unscrew the nut (5) securing the ground jumper(7) to the bracket stud. Remove the nut, lockwasher (6), and flat washer (4).

7. Remove the 16 socket screws (2) securing thecover (17) to the manifold and lift the cover offthe manifold.

8. Remove the filter discs, valve bladders, andbladder supports (10, 11, 12) from the manifold.

9. Remove the bladder supports from the valvebladders.

10. Blow out the manifold, cover, and bladdersupports. Make sure all traces of powder havebeen removed.

11. Insert the bladder supports into the new valvebladders, with the hole closest to the end of thesupport going in first.

12. Insert the new valve bladders into the manifold,with the flat edges on the flanges facing to thecenter of the manifold.

13. Install the new filter discs on the cover.

14. Install the cover on the manifold and thread the16 screws in finger tight.

15. Tighten the screws in a crisscross pattern, aturn at a time, until all are tight. Be careful notto overtighten the screws or the manifoldthreads could be damaged.

16. Secure the ground strap to the module bracketwith the flat washer, lock washer, and nut.

17. Install the manifold on the panel.

18. Slide the lock knobs, then the O-rings (9), onthe powder tubing.

19. Insert the tubing into the manifold ports until itbottoms out, then screw the lock knobs into theports until tight.



1

2

5

4

6

3

7

10

11

12

8

9

15

16

13

14

4

17

8A

88A

88A

88A

9

9

9

Figure 43 Manifold Exploded View



Dump Valve Repair

See Figure 44. Use the insertion tool shipped withthe HDLV pump pinch valve kit to install the dumpvalve pinch valve Refer to the HDLV pump manual1053244 for a detailed pictorial procedure.

1. Remove the 8 socket head screws from thevalve caps and remove the caps.

2. Place the valve body in a padded vise.

3. Grasp the large bottom flange of the pinchvalve and pull it out of the valve body.

4. Clean the valve body.

5. Install the insertion tool through the valve body.Put the UP end of the new pinch valve in thetool. The UP end of the pinch valve fits into thesmaller counterbore in the valve body.

6. Pinch the UP end of the pinch valve through theinsertion tool and pull on the other end of thetool until the pinch valve is through the valvebody.

7. Install the cap with the 12 mm fitting over theUP end of the pinch valve, and the cap with the8 mm fitting on the other side, and tighten thescrews in a crisscross pattern. Do notovertighten the screws or the valve bodythreads could be damaged.

1

2

3

4

UP end ofpinch valve

5

6

3

27

8

Figure 44 Dump Valve Cross-Section View



Parts To order parts, call the Nordson Industrial Coating Systems Customer Support Center at (800) 433-9319 orcontact your local Nordson representative.

System Manuals Manual Part No. Title/Contents

1102101 Color-on-Demand System: Installation, repair, parts lists, diagrams, and schematicsfor system, pump control panel, color change controller and panel, manifold, anddump valve.

1081751 Color-on-Demand System Operator Card: Operation and color changing

1077434 Manual Spray Gun: Installation, troubleshooting, repair, parts

1102106 Manual System: Configuration, preset setup, troubleshooting, parts lists for manualgun controller and pump panel.

1081071 Manual Gun System Troubleshooting: Basic gun and pump troubleshooting

1081195 HDLV Pump, Manifold, and Circuit Board: Troubleshooting, repair, and parts

Single Gun SystemPart No. Description Quantity Note

OBSOLETE SYSTEM, Color-on-Demand, manual, single, Prodigy Generation III

1101388 � KIT, controller, manual, Prodigy, Generation III 1

1101491 � KIT, controller interface, Prodigy color change, Generation III 1

1077058 � GUN, manual, 95 kV, Prodigy, Generation II 1 A

- - - - - - � CONTROLLER, single pump, Prodigy wall mount 1

1080507 � KIT, ship-with, wall mount system, Prodigy II 1

1067148 � KIT, ship-with, Color-on-Demand, Prodigy 1

NOTE A: Part is obsolete.

Dual Gun System Part No. Description Quantity Note

OBSOLETE SYSTEM, Color-on-Demand, manual, dual, Prodigy Generation III

1101388 � KIT, controller, manual, Prodigy, Generation III 2

1101491 � KIT, controller interface, Prodigy color change, Generation III 2

1077058 � GUN, manual, 95 kV, Prodigy, Generation II 2 A

- - - - - - � CONTROLLER, dual pump, Prodigy wall mount 1

1080507 � KIT, ship-with, Prodigy wall mount 2

1067148 � KIT, ship-with, Color-on-Demand, Prodigy 2

NOTE A: Part is obsolete.

Spray Gun Body Repair KitPart No. Description Quantity Note1611771 KIT, repair, gun body, Prodigy, manual 1 A

NOTE A: Kit does not include nozzles.



Pump Panel Replacement Parts See Figure 45.

Item Part Description Quantity Note1 303132 VALVE, 3/4 in. I/O, air operated AR A

2 - - - - - - MANIFOLD ASSEMBLY, HDLV pump control AR B, E

3 1081194 PUMP ASSEMBLY, HDLV AR A

4 1043906 POWER SUPPLY, 24, 5, 12 VDC, 60 W 1 G

5 334805 FILTER, line, RFI, power, 10A 1

6 334806 SWITCH, round, 2 position, 90 degree 1

7 288806 CONTACT BLOCK, 2 N.O. contacts 1

8 1009090 FUSE, time delay, 215 series, 3.15 A, 5 x 20 mm 2

9 1099534 VALVE, solenoid, 3 port, 24 V, with adapter AR A, F

10 1101498 KIT, PCA replacement, Prodigy pump control 1 A, C

11 1062366 FILTER, air, 1/2 in. NPT 1

11A 1064136 � FILTER ELEMENT, air, 5 micron, AF40 1

12 901151 VALVE, ball, 1/2 in. NPT 1

13 1034396 MUFFLER, exhaust, 1/4 in. NPT male AR A

14 1064135 REGULATOR, manifold, modular style 5 D

15 1065536 GAUGE, air, 0−100 psi, 0−0.7 MPA, 1/8 RPT 5

NOTE A: Quantities for AR items vary depending on number of guns in system.

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

C: Board is shipped with 4-mm air tubing already installed in pressure transducer fittings. When replacingboard, set switch settings as shown on page 24 instead of those shipped with instruction sheet shippedwith board. You must also perform calibration procedure as described in Manual Gun Controller manual.

D: Regulators must be set to the pressure specified in Figure 3.

E: For manifold assembly part numbers refer to manual 1081195.

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

G: Power supply cover kit (1611787) available.

AR: As Required



1 1

11 9 9

6

4

10

5

7

13

12

13

8

13

11A

14

15

3

2

2

3

Figure 45 Pump Panel Components (Two-Gun Panel Shown)



Manifold Air and Powder Tubing Part Numbers See Figure 46.

Item Part Description Item Part Description

A 900740 10 mm 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 Clear polyethylene 1, 8900617 4 mm Clear polyurethane

E 900740 10 mm Blue polyurethane

Top of Manifold

Bottom of Manifold

A A

C B

F E

D

4 or 83 or 7

G

1 or 52 or 6H

Figure 46 Air and Powder Tubing Part Numbers



Color-on-Demand Controller and Control Panel Parts Controller Kit Parts

See Figure 47.

Item Part Description Quantity Note— 1101491 KIT, controller interface, Prodigy color change III 1

1 1101488 � CONTROLLER interface, Prodigy color change III 1 A

2 129592 � KNOB, clamping, M6 x 12 mm long 2

3 129590 � SPACER, cabinet, friction 2

4 982649 � SCREW, hex, machine, M10 x 22 mm 1

5 983405 � WASHER, lock, split, M10, steel, zinc 1

6 288828 � KIT, bracket, mounting, rail 1

7 982500 � SCREW, hex, machine, M8 x 16 mm 1

8 984707 � NUT, hex, M8, steel, zinc 1

9 240976 � CLAMP, ground w/wire 110 - - - - - - � BRACKET, base, manual control interface 111 - - - - - - � BRACKET, post, Prodigy, manual control 112 - - - - - - � BRACKET, mounting, U, Prodigy, manual control 1

NOTE A: See Figure 47 and accompanying parts list for serviceable parts.

2

7

45

8

9

1

1011

3

6

12

Figure 47 Controller Kit Parts



Controller Parts

See Figure 48.

Item Part Description Quantity Note— 1101488 CONTROLLER, interface, Prodigy color change III 1

1 1101458 � TERMINAL, display, COD Generation III 1 A

2 322404 � SWITCH, rocker, DPST, dust-tight 1

3 939122 � SEAL, conduit fitting, 1/2 in., blue 2

4 984526 � NUT, lock, 1/2 in. conduit 2

5 324343 � CONNECTOR, conduit, straight, 1/2 in. 1

6 984702 � NUT, hex, M5, brass 4

7 983401 � WASHER, lock, split, M5, steel, zinc 4

8 983021 � WASHER, flat, 0.203 x 0.406 x 0.040 in., brass 1

9 240674 � TAG, ground 4

10 271221 � LUG, 45, double, 0.250, 0.438 in. 2NOTE A: Use Retrofit Kit 1101490 to replace the Cimrex 69 display terminal with the Proface AGP3300 display

terminal.

Retrofit Kit

Item Part Description Quantity Note— 1101490 KIT, retrofit, display, COD Generation III 1

1 1101458 � TERMINAL, display, COD Generation III 111 - - - - - - � PLATE, adapter with studs 112 - - - - - - � GASKET, adapter plate 113 - - - - - - � PLATE, adapter 114 983102 � WASHER, lock, SPT, #6, steel, zinc, 14451−CA 415 984101 � NUT, hex, machine, #6−32, steel, zinc,

14441−CA4



2

1

3

4

53

67

89

9

10

7

6

1112

13

14

15

Figure 48 Controller Parts



Color Change Control Panel Parts

See Figure 49.

Item Part Description Quantity Note— - - - - - - CONTROLLER, Prodigy, single or dual color

changer1

1 1101489 � CONTROL UNIT, dual pump color changer,PLC

1 A

2 1101459 � CONTROL UNIT, single pump color changer,PLC

1 A

3 303132 � VALVE, 3/4 in. NPT, air operated AR B

4 1095074 � SWITCH, pressure, N.O., 30 psi AR B5 1068324 � VALVE, solenoid, 3 port, 24V, N.O., w/o leads AR C6 1068325 � VALVE, solenoid, 3 port, 24V, N.C., w/o leads AR C

NS 173101 � TUBING, polyethylene, 8 mm x 6 mm, natural AR D

NS 900742 � TUBING, polyurethane, 6/4 mm, blue AR D

NS 900618 � TUBING, polyurethane, 8 mm OD, blue AR D



NOTE A: Select appropriate control unit for your system. Parts breakdown on following pages.

H: One required per gun.

I: 31 N.O. valves and 1 N.C. valve required per gun.

J: Order in increments of one foot.

AR: As Required

NS: Not Shown



1,2

3

4

5

6

5

5

6

5

Gun A

Gun B

Figure 49 Color Control Panel Parts



Control Unit (PLC) Parts

See Figure 50.

Item Part Description Quantity Note− 1101489 CONTROL UNIT, dual pump color changer, PLC 1

− 1101459 CONTROL UNIT, single pump color changer, PLC 1

1 1105978 � CONTROLLER, programmed, COD, Gen III AR A, D

2 1064193 � MODULE, 8-channel digital input, Wago,750-430

AR B, D

3 1064195 � MODULE, 8-channel digital output, Wago,750-530

AR C, D

4 1064191 � MODULE, end, carrier, Wago, 750-600 1

5 1064192 � POWER SUPPLY, 90W, 24Vdc, 3.75 amps,DIN rail

1 D

NOTE A: Two required for dual control unit, one for single.

B: Four required for dual control unit, two for single.

C: Ten required for dual control unit, five for single.

D: Installation by a qualified Nordson service representative is recommended for these parts.

AR: As Required

NS: Not Shown



3

2

1

4

5

3

2

1

4

Figure 50 Control Unit (PLC) Parts



Ship-With Kit Parts

Part Description Quantity Note1067148 KIT, ship-with, Color-on-Demand system 1

1072866 � CABLE, Ethernet CAT5E, 50 ft 1

248375 � CONDUIT, flexible, bulk, 1/2 in. (50 ft) AR A1058224 � CONNECTOR, Ethernet, RJ45-to-IDC, CAT5 11078555 � BOX, surface mount, Ethernet 1

226690 � TUBING, polyurethane, 12/8 mm, blue (50 ft) AR A

1064948 � SWITCH, foot, air, 3-way, 100 psi AR900742 � TUBING, polyurethane, 6/4 mm, blue (100 ft) AR A1065711 � CABLE, Ethernet crossover, CAT5E, RJ45, 3 ft 1−−−−−− � UNION, reducer, 12 mm tube x 8 mm tube 1972141 � CONNECTOR, male, 6 mm tube x 1/8 in. unithread 2911110 � UNION, bulkhead, 12 mm tube x 12 mm tube 2933071 � TERMINAL, ringtong, ins, 22−18, 10 1

NOTE A: Order replacements in increments of one foot.

AR: As Required

Color Change Manifold Parts

See Figure 51.

Item Part Description Quantity Note− 1094892 MANIFOLD, module, Color-on-Demand, assembly1 972126 � CONNECTOR, male, elbow, 6 mm tube x

1/8 in. unithread10

2 981225 � SCREW, socket head, 1/4−20 x 0.625 in. 163 1045837 � SCREW, pan head, M5 x 12, w/lockwasher 14 983021 � WASHER, flat, 0.203 x 0.406 x 0.040, brass 25 984702 � NUT, hex, M5, brass 16 983401 � WASHER, lock, split, M5, steel, zinc 17 246458 � JUMPER, ground, 4 in. 18 1047934 � KNOB, lock, powder tube 12

8A 940117 � O-RING, silicone, .312 x .438 x .063 in. 12 C9 945115 � O-RING, Viton, 8.00 x 2.00 12 A10 1080408 � DISC, filter, Prodigy HDLV pump 10 B11 - - - - - - � SUPPORT, Color-on-Demand bladder 1012 - - - - - - � VALVE BLADDER, color changer, 0.12 W, ,

Color-on-Demand10 B

13 - - - - - - � MANIFOLD, color changer, Color-on-Demand 114 - - - - - - � BRACKET, Prodigy color changer 115 983409 � WASHER, lock, split, M6, steel, zinc 216 982499 � SCREW, pan head, slotted, M6 x 12, zinc 217 - - - - - - � COVER, manifold, color changer,

Color-on-Demand1

NOTE A: Available in packages of 12, order 1065983 KIT, Color-on-Demand, O-Ring, 12 pack.

B: Available in packages of 10 bladders and 10 filter discs, order 1065982, KIT, Color-on-Demand, bladder,10 pack.

C: Internal O-ring for lock knob.



1

2

5

4

6

3

7

10

11

12

8

9

15

16

13

14

4

17

8A

88A

88A

88A

9

9

9

Figure 51 Color Change Manifold Parts



Dump Valve Parts

See Figure 52.

Item Part Description Quantity Note− 1074720 VALVE, dump, Color-on-Demand 11 971104 � CONNECTOR, male, 12 mm x 1/4 in. unithread 12 1064886 � SCREW, socket head, M6 x 14, zinc 83 - - - - - - � CAP, dump valve, Color-on-Demand 24 1066626 � VALVE, pinch, HDLV pump 1 A5 1074028 � BODY, dump valve, Color-on-Demand 16 972126 � CONNECTOR, male, elbow, 6 mm x 1/8 in.

unithread1

7 971121 � CONNECTOR, male, 8 mm x 1/4 in. unithread 18 1075460 FILTER, inline, 1/8-in. NPT 1

NOTE A: To replace, order 1066626 KIT, dump valve, pinch valve, 4 pack. Use insertion tool shipped with pumppinch valve kit to install.

1

2

3

4

UP end ofpinch valve

5

6

3

27

8

Figure 52 Dump Valve Parts



15 FT (4.6M)POWER CORD

FUSE HOLDERS FUSES

BROWN

BLUE

BLUE

N (L2 − NEUTRAL)

BROWN

L (L1 − HOT)

60W POWER SUPPLY

GREEN/YEL

(INSIDE ENCLOSURE BOTTOM)

GND

BLACKGRAY

ORANGERED

SK2

456

23

1

L (3)SK1

N (1)FILTER334805

F2 F1

251

34

2414

2313

FLOW ACTUATORHARNESSES

+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

1 1

J2PUMP A

SOL

1

J1PATT A

SOL

1

P4

J5

P2PUMP

BP1

PUMP A

P5CANOUT

P6CAN IN

W1CAN BUS

TERM

1 1

P3DC

POWER

BLU

EW

HIT

E

GR

N/Y

EL

BR

NB

LUE

BLACK

RED

GREEN/YEL

RED

BLACK

GR

AY

BLA

CK

RE

D

OR

AN

GE

+24VDC BLUE

GND GRN/YELPATTERN BRN

+24VDC BLUE

GND GRN/YELFLOW BRN

SOL.7

5

3

7

2

4

6

1

SOL.2

SOL.5SOL.4

SOL.1

SOL.3

SOL.6

BR

OW

N

BLU

E

BR

OW

N

BLU

E

BLU

E

BLU

E

BR

OW

N

BR

OW

N

GND(ENCLOSURE)

GND(SUB PANEL)

HDLV PUMP CONTROL MANIFOLD1

TO HDLV PUMPCONTROL MANIFOLD 1SOLENOIDS 1 − 7

PUMP CONTROLHARNESS

PRODIGY IIIDUAL PUMPCONTROLLER

(PRODIGY NETWORK CABLE)NET/PWR 1

POWER SUPPLYHARNESS

SWITCH CONTACT BLOCK

A.C. POWER HARNESS(FUSE HOLDER TO FILTER)

(SWITCH TO FILTER)A.C. POWER HARNESS

(SWITCH TO POWER SUPPLY)A.C. POWER HARNESS

(JUMPER)A.C. POWER HARNESS

JUMPER

TERMINALBLOCK

GND − (INSIDEENCLOSURE BOTTOM)

DRAIN

SETTINGSW2

OPEN

BIT 1

OPEN

BIT 2 BIT 4

OPEN

BIT 3

OPEN

1 32 4

1

23

456

78

9 0

SW1

MANUAL GUN SYS.CLOSEDDEFAULT

DETAIL B

SW2

OPEN

21 43SW2

DETAIL A

SW1

DETAIL A

DETAIL B

DETAILC

= PUSH THIS SIDE OF SWITCH

OPEN CLOSEDOPEN COLOR ON DEMANDCLOSED

RED

REDRED

BLACKBLACKBLACK

ORANGE

GRAY

+24VDC BLUEFLOW BRN

1

BR

NB

LUEB

LUE

BR

NG

RN

/YE

L

DETAIL A

BLACK

21

6

43

5

7

SOL.7

2

SOL.2

SOL.5

SOL.1

SOL.3SOL.4

SOL.6

1 1

BLA

CK

1

RE

D

OR

AN

GE

GR

AY

34 12

312 4

DETAIL B

GRAY

ORANGERED

BLACK

BLU

EW

HIT

E

VACUUM, SOLENOID 714SOLENOID COMMON (+24 VDC)RED7 BLACK

DELIVERY PINCH VALVE, SOLENOID 6

DELIVERY PINCH VALVE, SOLENOID 1PRESSURE SOURCE, SOLENOID 2SUCTION PINCH VALVE, SOLENOID 3SUCTION PINCH VALVE, SOLENOID 4PRESSURE SOURCE, SOLENOID 5

SOLENOID COMMON (+24 VDC)

SOLENOID COMMON (+24 VDC)SOLENOID COMMON (+24 VDC)SOLENOID COMMON (+24 VDC)SOLENOID COMMON (+24 VDC)SOLENOID COMMON (+24 VDC)

COLORNO.

RED

REDRED

6

45

RED

REDRED

23

1

WIREPINNO.FUNCTION COLOR

13

1112

BLACKBLACKBLACK

910

8

BLACKBLACKBLACK

PIN WIREFUNCTION

PUMP CONTROL HARNESSES

P3DC

POWER

W1CAN BUS

TERMP6

CAN IN

P5CANOUT

P4

PUMP BPUMP A

OPEN

SW2

SW1

PRODIGY IIIDUAL PUMPCONTROLLER AB

J5

P1PUMP B

DETAILC

600 MMPUMP CONTROL

HARNESS

TO HDLV PUMPCONTROL MANIFOLD 2

SOLENOIDS 1−7

POWER SUPPLY HARNESS

SOL

+24VDCRED

PATT BSOL

PUMP B PUMP ASOL

PATT ASOL

P2PUMP

B SOL

J1J2J3J4

1 111 1 1

FLOW ACTUATORHARNESSES

GR

N/Y

EL

GR

N/Y

EL

+24VDC BLUE

GND GRN/YELPATTERN BRN

GND GRN/YEL

HDLV PUMP CONTROL MANIFOLD

(PRODIGY NETWORK CABLE)NET/PWR 2

RED

REDBLACK

BLACK

SHORTPOWER SUPPLY

HARNESS

JUMPER

GNDINSIDE DOOR

GND(ENCLOSURE)

DRAIN

SWITCH SHOWNSET FOR COLOR−ON−DEMAND SYSTEM

zl

Figure 53 Pump Control Panel Wiring Diagram



XXXX

SEE PUMP CONTROLBOARDDETAILS

(TOP VIEW)

(BOTTOM VIEW) (BOTTOM VIEW)

PUMP/MANIFOLD

1

(TOP VIEW)

INPUT AIR

PUMP/MANIFOLD

2

2 1

PURGEMANIFOLD

1 2

FILTER

REGULATORASSEMBLY

PURGE PILOTMANIFOLD

PINCH SELECTMANIFOLD

PINCH LOW

PINCH HIGH

FLOW CONTROL

VACCUUM

PURGE

A

K

R

E EE E

D

D

D

DC

C

M

L

L

G

F

I

H

O

N P

B

Q

J

S

3 4

21

124 36 58 7

VENTEXHAUST EXHAUST

1/2 NPT PIPE PLUGFOR 1 PUMP CONTROLLER

(SEE DETAIL)

(SEE DETAIL)

PURGE VALVE 1 PURGE VALVE 2

T

T

U

CHECKVALVE

CHECKVALVE

FREE FLOW

FREE FLOW

FREEFLOW

(12MM TUBE FITTING)

PINCH SELECT MANIFOLD DETAIL(CONFIGURATION FOR 1 PUMP CONTROLLER)

P

R

USE PLUGSUPPLIEDWITH ITEM 7


PURGE PILOT MANIFOLD DETAIL(CONFIGURATION FOR 1 PUMP CONTROLLER)

R

P


PINCH SELECT MANIFOLD DETAIL(CONFIGURATION FOR 2 PUMP CONTROLLER)

R

P


PURGE PILOT MANIFOLD DETAIL(CONFIGURATION FOR 2 PUMP CONTROLLER)

R

P

TO: COLORCHANGE PANELPURGETO: COLOR

CHANGE PANELMAIN

”AUX. 2”

X

W

FROM:COLOR CHANGEMANIFOLDS ”A”

FROM:COLOR CHANGEMANIFOLDS ”B”

ONE BOARDPER PUMP

XDCR1XDCR2

2 1

34

Figure 54 Pump Contol Panel Pneumatic Diagram (Sheet 1 of 2)



PUMP CONTROL BOARD −

8 7 6 5 4 3 2 1

(BOTTOM VIEW)

3 4

21

PUMP/MANIFOLD

1

PUMP CONTROL

BOARD ”A” DETAIL

V

13

4 2

A

PUMP/MANIFOLD

PUMP CONTROL

BOARD ”B” DETAIL

B

PUMP CONTROL BOARD −

Y

(BOTTOM VIEW)

78

56

68 7 5 4 3

8 6

7 5

2 1

2

Figure 55 Pump Control Panel Pneumatic Diagram (Sheet 2 of 2)



5 6

32

ENCLOSURE

ADAPTER PLATE

ETHERNET CABLE(FIELD INSTALLED)

PART OFRECEPTACLE

6 PIN

GROUND WIRE

RECEPTACLE 6 PINROCKER SWITCH

FROM ETHERNET INSULATIONDISPLACEMENT CONNECTOR(PART OF COLOR CHANGECONTROLLER)

GR

EE

N/Y

ELL

OW

GREEN/YELLOW

RED

YELLOW

GR

EE

N/Y

ELL

OW YE

LLO

W

.50 STRAIGHTCONDUIT CONNECTOR

TO BACK PLATEGROUND STUD

YELLOW

WHITE

GREEN

BLACK

GRAY

(ENCLOSURE GROUND) (ENCLOSURE GROUND)

USB

COM 1

COM 2

LANRJ−45

CONNECTOR

Pro−faceAPG3300−T1−D24

5 6

32

Figure 56 Color-on-Demand Controller Wiring Diagram



”AU

X 2

”P

UM

P C

AB

INE

TB

OT

TO

M

JF

RO

M P

UR

GE

RE

GU

LAT

OR

Y

FR

OM

FLO

WR

EG

ULA

TO

R Y

BU

LKH

EA

D

B

DE

CO

LOR

CH

AN

GE

MA

IN

C11AE

C10AE

C14AE

C13AE

C12AE

C9AE

C15AE

O P

61

A

FJ

D2BE

P1BE

P2BE

C25BE

C28BE

C27BE

C26BE

C13BE

C15BE

C14BE

C9BE

C12BE

C11BE

C10BE

FJ

G

D2AE

P1AE

P2AE

C27AE

C28AE

C26AE

C25AE

L

P1B

P

C11

BP

C14

BP

C6B

P

C15

BP

C7B

P

C13

BP

C5B

P

C12

BP

C4B

P

I

C9B

P

C1B

P

C10

BP

C2B

PC

3BP

C8B

P

D1B

P

C1AE

C2AE

D1AE

C5AE

C4AE

C7AE

C8AE

C6AE

C3AE

C22BE

C23BE

C24BE

C21BE

C18BE

C17BE

C20BE

C19BE

C6BE

C7BE

C8BE

C5BE

C1BE

C2BE

C4BE

C3BE

C16BED1BE

C24AE

C23AE

C21AE

C22AE

C20AE

C19AE

C18AE

C17AE

C16AE

L

N

C8A

P

D1A

P

P1A

P

M

C13

AP

C5A

P

H

C14

AP

C6A

P

C15

AP

C7A

P

C12

AP

C4A

P

C11

AP

C3A

P

C9A

P

C1A

P

C10

AP

C2A

P

K

FO

OT

SW

ITC

HS

OU

RC

E A

& B

CA

BIN

ET

RE

AR

C27

BP

C19

BP

CO

LOR

CH

AN

GE

DIS

TR

IBU

TIO

N M

AN

IFO

LD

P2B

P

C22

BP

SW

BR

TN

C23

BP

D2B

PC

28B

P

C21

BP

C20

BP

C25

BP

C17

BP

C26

BP

C18

BP

C24

BP

C16

BP

B

P1B

P1A

C24

AP

C16

AP

D2A

P

C21

AP

CO

LOR

CH

AN

GE

DIS

TR

IBU

TIO

N M

AN

IFO

LD

P2A

PS

WA

RT

N

C22

AP

C23

AP

C27

AP

C28

AP

C20

AP

C19

AP

C26

AP

C25

AP

C17

AP

C18

AP

A

1/2

NP

T P

IPE

PLU

G F

OR

1 P

UM

PC

ON

TR

OLL

ER (O

UT

OF

PO

SIT

ION

− F

ITT

ING

S S

HO

WN

RO

TAT

ED

FO

R C

LAR

ITY

)

(PU

MP

CO

NT

RO

L P

AN

EL)

(PU

MP

CO

NT

RO

L P

AN

EL)

Figure 57 Color Change Control Panel Internal Pneumatic Diagram (Dual Unit Shown)



CO

LOR

CH

AN

GE

DIS

TR

IBU

TIO

N M

AN

IFO

LD

C28

P2

C26

C27

C24

C25

C22

C23

C20

C21

C10

C12

C14

C16

C18

C11

C13

C15

C17

D1

C2C4

C6

C8

C1

C3

C5

C7

C19 C9

D2

P1

C14

AP

C7A

P

C15

AP

C5A

PC

6AP

C13

AP

C22

AP

C23

AP

SW

AR

TN

C21

AP

P2A

PD

2AP

C25

AP

C17

AP

C9A

P

C1A

P

C11

AP

C3A

PC

4AP

C12

AP

C2A

P

C10

AP

C27

AP

C19

AP

C20

AP

C28

AP

C18

AP

C26

AP

D1A

P

C8A

P

C16

AP

C24

AP

R

S

TT

S

R

V W W

TO

PU

MP

1

(SE

E 1

0669

32)

TO

DU

MP

Q

P1A X

A

U

TO

PU

MP

2(S

EE

106

6932

)

U

RW

R

SW

S

TV

TO

DU

MP

CO

LOR

CH

AN

GE

DIS

TR

IBU

TIO

N M

AN

IFO

LD

B

D2

T

X

Q

C19

BP

C27

BP

C3B

P

C11

BP

C18

BP

C16

BP

C17

BP

C1B

P

C9B

P

D1B

P

C8B

P

C2B

P

C10

BP

C25

BP

C24

BP

C26

BP

C22

BP

C14

BP

C21

BP

C20

BP

C13

BP

C4B

P

C12

BP

C5B

PC

6BP

C28

BP

D2B

PP

2BP

C23

BP

C7B

P

C15

BP

SW

BR

TN

P1B

DU

MP

2

VA

LVE

CO

LOR

28−

P2

CO

LOR

10−

19

DU

MP

1−C

OLO

R9

DU

MP

2

VA

LVE

(D1 −

C9)

(C10

− C

19)

(C20

− P

2)

D1

C2C4

C6

C8

C1

C3

C5

C7

C9

C10

C12

C14

C16

C18

C11

C13

C15

C17

C19

C28

P2

C26

C27

C24

C25

C22

C23

C20

C21

P1

Figure 58 Color Change Control Panel External Pneumatic Diagram (Dual Unit Shown)



PLC A

C20

BE

C4B

E

P2B

EC

14B

E

P1B

EC

15B

E

C25

BE

C26

BE

C28

BE

C27

BE

D2B

E

C22

BE

C21

BE

C24

BE

C23

BE

C9B

E

C11

BE

C13

BE

C12

BE

C10

BE

C7B

E

C8B

E

C6B

E

C5B

E

POWER

SUPPLY

C18

BE

C17

BE

C16

BE

C19

BE

C2B

E

C1B

E

D1B

E

C3B

E

PLC B

C4A

EC

20A

E

C14

AE

P2A

E

C15

AE

P1A

E

C10

AE

C13

AE

C12

AE

C11

AE

C25

AE

C28

AE

D2A

E

C26

AE

C27

AE

C22

AE

C24

AE

C23

AE

C21

AE

C9A

E

C6A

E

C8A

E

C7A

E

C5A

E

SWBRTN

C17

AE

C18

AE

C19

AE

C16

AE

C1A

E

C2A

E

C3A

E

D1A

E

SWARTN

NETWORKB

POWERB

NETWORKA

POWERA

(C.O.D. INTERFACE

POWER CABLE)

ENCLOSURE REAR)GND − (INSIDE

POWER B

DRAIN DRAIN

POWER A(C.O.D. INTERFACE

POWER CABLE)

BLU

E

BR

OW

N

14

13

24

23

RED

BLUEWHITE

BLACK

BLACK

REDBLUEWHITE

GREEN/YELLLOWBLUE

BROWN

BLU

E

WH

ITE

BLU

E

WH

ITE

NC (WHITE)

COM (BLUE)

B

TO: PRODIGY GEN IIIDUAL PUMP

CONTROLLERA

PRODIGY GEN IIICOLOR CHANGE

PURGE PILOTMANIFOLD

COLOR CHANGEDISTRIBUTION MANIFOLD

CONTACT BLOCK

DETAIL A

AB

COLOR CHANGEDISTRIBUTION MANIFOLD

(SEE SCHEMATICS)

COMMUNICATIONHARNESS


PRESSURE SWITCHHARNESS

FOOT SWITCH HARNESS FOOT SWITCH HARNESS

ETHERNET CROSSOVERCABLE 1065711

(FIELD INSTALL)

COLOR CHANGE CONTROLLERINTERFACE CABLE(SEE DETAIL A)

GR

EE

N/Y

ELL

OW

GND

(INSIDE PUMP

ENCLOSURE BOTTOM)

COLOR CHANGEPOWER CORD

(PART OF PUMP CONTROLLER

W/BLU BLU

DETAIL B

SEE DETAIL B

ETHERNET INSULATIONDISPLACEMENT CONNECTORMODULE 1058224 COLOR CODE ”B”(FIELD INSTALL)

ETHERNET CONNECTORMODULE MOUNTING BOX1078555 (FIELD INSTALL)

50 FT. ETHERNET PATCH CABLETO BE PULLED THRU CONDUIT FROM PRODIGYCOLOR CHG CONTROLLER INTERFACE (FIELD INSTALL − TRIM TO LENGTH AND CONNECT

FIELD INSTALLATION

36 36

TO: PRODIGY GEN IIIDUAL PUMP

CONTROLLER

SUB PANEL

GND

C.O.D

ENCLOSURE

GND

C.O.D

ENCLOSURE

36

SHIELD TO GROUND)

BRN

GRN

ORG

BLU

BRN

GRN

ORG

BLU

W/

W/

W/

W/

BRN

GRN

ORG

BLU

BRN

GRN

ORG

BLU

W/

W/

W/

W/

W/GRN GRN

W/ORG ORG W/BRN BRN

Figure 59 Color Change System Wiring Diagram (Dual Unit, Sheet 1 of 2)



BLACK

1

8

1

4 3 2 1

8

1

J3PATT B

SOL

1

J4

PUMP B

1 1

J2

PUMP ASOL

1

J1PATT A

SOL

1

P4

J5

P2PUMP

B

P1PUMPA

P5CANOUT

P6CAN IN

W1CAN BUSTERM

1 1

P3DC

POWER

PIN

CH

1P

INC

H 2

PU

RG

E 1

PU

RG

E 2

+24VDC RED

RE

DB

LAC

K

RE

DB

LAC

K

PINCH SELECTMANIFOLD

RE

DB

LAC

K

RE

DB

LAC

K

PRODIGYDUAL PUMPCONTROLLER

1047464

PURGE PILOTMANIFOLD


OPEN

21 43 SW2

SW1A

J5

P4

1

W1CAN BUS

TERM

P5CANOUT

P6CAN IN

1 1

PRODIGY GEN IIIDUAL PUMPCONTROLLER

P3DCPOWER

34 2 1

BSW1

P2PUMP

B

1

8

1

J3PATT B

SOL

J4PUMP B

1 1

J2PUMP A

SOL

1

P1PUMP

A

J1PATT A

SOL

1

8

1

BLUEWHITE

+24VDC REDBLACK

(BLUE)

(WHITE)

(BLUE)

(WHITE)

CVB (BLUE)

CVB (WHITE)CABLE #3A

DOC (WHITE)

DOC (BLUE)CABLE #4A


(WH

ITE

)

(BLU

E)

CA

BLE

#1B

TO: PLC B(SEE SCHEMATIC)

TO: PLC A(SEE SCHEMATIC)

(PART OF PUMP CONTROLLER PANEL)

(WH

ITE

)

(BLU

E)

CA

BLE

#2B

WHITE

BLUE

TO: PLC B(SEE SCHEMATIC)

CABLE #3B

CABLE #4B(WHITE)

(BLUE)

(BLUE)(WHITE)

CVB (BLUE)

CVB (WHITE)

DOC (BLUE)

DOC (WHITE)

BLUE

WHITE

WHITEBLUE

TO: PLC A(SEE SCHEMATIC)

CA

BLE

#2A

CA

BLE

#1A

(BLU

E)

(BLU

E)

(WH

ITE

)

(WH

ITE

)

JUMPER

GND(C.O.D. ENCLOSURE)

JUMPER


GND(INSIDE DOOR)

GND(SUB PANEL)

GND(PUMP CTRL ENCLOSURE)

GND(C.O.D ENCLOSURE)

JUMPER

GND(C.C. MANIFOLD BRKT)


JUMPER

PINCH 2

PURGE 2

PU

RG

E1

PIN

CH

1

SOL

OPEN

21 43 SW2

SOL

(LABEL ”B”)

(LABEL ”B”)

(LABEL ”A”)

LABEL “1”

(LABEL “A”)

LABEL “2”

LABEL “2”

36

39 33 33

Figure 60 Color Change System Wiring Diagram (Dual Unit, Sheet 2 of 2)



FROM

PUMP

CONTROL

BOX

POWER

CABLE

1000 (HOT,BROWN)

1010 (NEUT,BLUE)

1020 (GND,GREEN\YELLOW)

PWR1, POWER SUPPLY

OMRON

L

N

G

100−240VAC

DC ON

VR ADJ

24VDC5A

−V

+V

S8VS12

024

1030 (GND,GREEN\YELLOW, 16 GA)

(GREEN \

YELLOW)

DIN RAIL CHASSIS

GROUND

TB1A

1070 (24COM,BLACK)

1080 (24VDC,RED)

122122

10801070

121

116

120

119

118

117

115

114

113

112

107

111

110

108

109

106

105

104

103

100

102

101

143

138

142

141

140

139

137

136

135

134

129

133

132

130

131

128

127

126

125

122

124

123

CCSA (BLUE)

CVBA (BLUE)

SCCA (BLUE)

DOCA (BLUE)

1120 (BLACK)

PS1 (WHITE)

1080 (24VDC,RED)

SW1A (RED)

(BLUE)

TB12A

(BLUE)

TB11A

(BLUE)

TB10A

(BLUE)

TB9A

(BLUE)

TB8A

(BLUE)

TB7A

(BLUE)

TB6A

(BLUE)

TB5A

(GRAY)

TB4A

(GRAY)

TB3A

(GRAY)

TB2A

D2AE (BLACK)D1AE (BLACK)C28AE (BLACK)C27AE (BLACK)C26AE (BLACK)C25AE (BLACK)C24AE (BLACK)

C23AE (BLACK)C22AE (BLACK)C21AE (BLACK)C20AE (BLACK)C19AE (BLACK)C18AE (BLACK)C17AE (BLACK)C16AE (BLACK)C15AE (BLACK)C14AE (BLACK)C13AE (BLACK)C12AE (BLACK)C11AE (BLACK)C10AE (BLACK)C9AE (BLACK)C8AE (BLACK)C7AE (BLACK)C6AE (BLACK)C5AE (BLACK)

C2AE (BLACK)

C4AE (BLACK)C3AE (BLACK)

C1AE (BLACK)P2AE (BLACK)

24COM (BLACK)

+24V SW1A−5 (RED)

SW1A−2 (WHITE)

SW1A−3 (BLUE)

CABLE

POWER

DISPLAY ”A”

FROM

4

3

2

1

4

3

2

1

4

3

2

1

4

3

2

1

4

3

2

1

4

3

2

1

4

3

2

1

4

3

2

1

4

3

2

1

4

3

2

1

4

3

2

1

10701080

200 200

121121

RSIA(WHITE)

23

13

BROWN

BLUE

AC POWERSWITCH

GREEN\YELLOW

GROUND STUD

USE 8 POS.

JUMPER

GROUND (BARE)

STUD

SUB PANEL

ENCLOSURE

STUD

BRAIDED JUMPER

BRAIDED JUMPER

STUD

ENCLOSURE

DOOR

STUD

BRAIDED JUMPER

121

1120

122

1071 (BLACK)

1120 (BLACK)

1011

(B

LUE

)

1001

(B

RO

WN

)

CRI

P1AE (BLACK)

Figure 61 Color-on-Demand Control Panel Schematic (Dual Unit, Sheet 1 of 10)



243

238

242

241

240

239

237

236

235

234

229

233

232

230

231

228

227

226

225

222

224

MD2A, 8 PT. SOURCE

430

1,IN1

750−

2,IN3

3,IN5

4,IN7

5,IN2

6,IN4

7,IN6

8,IN8

INPUT, POS. 1

SW1A (RED)

RS1A (BLUE)

CCSA (BLUE)

CCSA (WHITE)

CVBA (BLUE)

CVBA (WHITE)

PS1 (BLUE)

DOCA (BLUE)

DOCA (WHITE)

FROMPUMP

FROMPUMP

PS1 (WHITE)

CABLE #2A

CABLE #3A

COM

PRESSURE SWITCH

PS1 NC

CABLE #4A

11

223

PS1 (BLACK)

1080 1070

143143

TB1A

1030 (GND,GREEN/YELLOW)

1070 (24COM,BLACK)

1080 (24VDC,RED)

BLACK

RED

24V

750−

842

+

_

0V

+

_

WA

GO

I/O

SY

ST

EM

BUS CONTROLLER

MD1A, ETHERNET FIELD−

PS2A

FOOT SWITCH A

PRESSURE SWITCHRS1A (WHITE) 2 2

INPUT 7 SPARE 1

INPUT 8 SPARE 2

MD3A, 8 PT. SOURCE

1,IN1

5,IN2

2,IN3

6,IN4

3,IN5

7,IN6

4,IN7

8,IN8

750−

430

RS2A

BIT5A MSB

BIT4A

BIT3A

BIT2A

BIT1A LSB

COLOR CHG W/SUCTION LINE PURGE

SPARE 4

REMOTE PLC INTERFACE

COLOR CHANGE

SELECT & STROBE

RJ−45

MALE

(DESIGNATED INPUTS)

VIA ”AUX. 1”

CONTROLPANEL

CONTROLPANEL




321

316

320

319

318

317

315

314

313

312

307

311

310

308

309

306

305

304

303

300

302

301

343

338

342

341

340

339

337

336

335

334

329

333

332

330

331

328

327

326

325

322

324

323

FROM PUMPCABLE #1A

SCCA (BLUE)

SCCA (WHITE)

MD4A, 8 PT. SOURCE

OUTPUT, POS. 2

RM1A (RED)

SPARE(CCD)

P2AE (RED)

C28AE (RED)

C27AE (RED)

C26AE (RED)

C25AE (RED)

P2AE

VALVE

C28BE

VALVE

C27AE

VALVE

C26AE

VALVE

C25AE

VALVE

C28AE (BLACK)

C27AE (BLACK)

C26AE (BLACK)

C25AE (BLACK)

P2AE (BLACK)

1,OUT1

5,OUT2

2,OUT3

6,OUT4

3,OUT5

7,OUT6

4,OUT7

8,OUT8

750−

530

MD5A, 8 PT. SOURCE

OUTPUT, POS. 3

1,OUT1

5,OUT2

2,OUT3

7,OUT6

3,OUT5

6,OUT4

4,OUT7

8,OUT8

750−

530

C24AE (BLACK) C24AE

VALVE

C24AE (RED)

C23AE (BLACK) C23AE

VALVE

C23AE (RED)

C22AE (BLACK)

C21AE (BLACK)

C20AE (BLACK)

C19AE (BLACK)

C18AE (BLACK)

C17AE (BLACK)

C22AE

VALVE

C21AE

VALVE

C20AE

VALVE

C19AE

VALVE

C18AE

VALVE

C17AE

VALVE

C22AE (RED)

C21AE (RED)

C20AE (RED)

C19AE (RED)

C18AE (RED)

C17AE (RED)

MD6A, 8 PT. SOURCE

OUTPUT,POS. 4

C16AE (BLACK)

C15AE (BLACK)

C14AE (BLACK)

C13AE (BLACK)

C12AE (BLACK)

C11AE (BLACK)

C10AE (BLACK)

C9AE (BLACK)

C16AE

VALVE

C15AE

VALVE

C14AE

VALVE

C13AE

VALVE

C12AE

VALVE

C11AE

VALVE

C10AE

VALVE

C9AE

VALVE

C16AE (RED)

C15AE (RED)

C14AE (RED)

C13AE (RED)

C12AE (RED)

C11AE (RED)

C9AE (RED)

C10AE (RED)

1,OUT1

5,OUT2

2,OUT3

6,OUT4

3,OUT5

7,OUT6

4,OUT7

8,OUT8

750−

530

MD7A, 8 PT. SOURCE

OUTPUT, POS. 5

5.OUT2

2,OUT3

1,OUT1

6,OUT4

3,OUT5

7,OUT6

4,OUT7

8,OUT8

750−

530

C7AE (BLACK)

C8AE (BLACK)

C6AE (BLACK)

C5AE (BLACK)

C3AE (BLACK)

C2AE (BLACK)

C1AE (BLACK)

C4AE (BLACK)

C8AE

VALVE

C7AE

VALVE

C6AE

VALVE

C5AE

VALVE

C4AE

VALVE

C3AE

VALVE

C2AE

C1AE

VALVE

VALVE

C7AE (RED)

C8AE (RED)

C6AE (RED)

C5AE (RED)

C4AE (RED)

C3AE (RED)

C2AE (RED)

C1AE (RED)

4. 4.

FLOW CONTROLBOARD A




421

416

420

419

418

417

415

414

413

412

407

411

410

408

409

406

405

404

403

400

402

401

443

438

442

441

440

439

437

436

435

434

429

433

432

430

431

428

427

426

425

422

424

423

MD8A, 8 PT.SOURCE

OUTPUT, POS. 6

1,OUT1

5,OUT2

6,OUT4

3,OUT5

2,OUT3

7,OUT6

4,OUT7

8,OUT8

750−

530

D1AE (BLACK)

D2AE (BLACK)

D1AE

VALVE

D2AE

VALVE

D1AE (RED)

D2AE (RED)

OUTPUT 36 SPARE 2

OUTPUT 37 SPARE 3

OUTPUT 38 SPARE 4

OUTPUT 39 SPARE 5

VFD HIGH SPEED

MD9A,BUS END

POS. 7

1

5

2

6

3

7

4

8

750−

600

4.

P1AE (BLACK) P1AE

VALVE

P1AE (RED)




1030 (GND,GREEN\YELLOW)

(GREEN \

YELLOW)

DIN RAIL CHASSIS

GROUND

TB1B

521

516

520

519

518

517

515

514

513

512

507

511

510

508

509

506

505

504

503

500

502

501

543

538

542

541

540

539

537

536

535

534

529

533

532

530

531

528

527

526

525

522

524

523

CCSB (BLUE)

CVBB (BLUE)

SCCB (BLUE)

DOCB (BLUE)

(BLUE)

TB12B

(BLUE)

TB11B

(BLUE)

TB10B

(BLUE)

TB9B

(BLUE)

TB8B

(BLUE)

TB7B

(BLUE)

TB6B

(BLUE)

TB5B

(GRAY)

TB4B

(GRAY)

TB3B

(GRAY)

TB2B

D2BE (BLACK)D1BE (BLACK)C28BE (BLACK)C27BE (BLACK)C26BE (BLACK)C25BE (BLACK)C24BE (BLACK)

C23BE (BLACK)C22BE (BLACK)C21BE (BLACK)C20BE (BLACK)C19BE (BLACK)C18BE (BLACK)C17BE (BLACK)C16BE (BLACK)C15BE (BLACK)C14BE (BLACK)C13BE (BLACK)C12BE (BLACK)C11BE (BLACK)C10BE (BLACK)C9BE (BLACK)C8BE (BLACK)C7BE (BLACK)C6BE (BLACK)C5BE (BLACK)

C2BE (BLACK)

C4BE (BLACK)C3BE (BLACK)

C1BE (BLACK)P2BE (BLACK)

CABLE

POWER

DISPLAY ”B”

FROM

4

3

2

1

4

3

2

1

4

3

2

1

4

3

2

1

4

3

2

1

4

3

2

1

4

3

2

1

4

3

2

1

4

3

2

1

4

3

2

1

4

3

2

1

RSIB(WHITE)

PWR1 GND

USE 8 POS.

JUMPER

GROUND (BARE)

SW1B−3 (BLUE)

SW1B−2 (WHITE)

+24V SW1B−5 (RED)

24COM (BLACK)

SW1B (RED)

1080 (24VDC,RED)

1120 (BLACK)

121 121

600600

1080 1070

121

P1BE (BLACK)




621

616

620

619

618

617

615

614

613

612

607

611

610

608

609

606

605

604

603

600

602

601

643

638

642

641

640

639

637

636

635

634

629

633

632

630

631

628

627

626

625

622

624

MD2B, 8 PT. SOURCE

430

1,IN1

750−

2,IN3

3,IN5

4,IN7

5,IN2

6,IN4

7,IN6

8,IN8

INPUT, POS. 1

SW1B (RED)

RS1B (BLUE)

CCSB (BLUE)

CCSB (WHITE)

CVBB (BLUE)

CVBB (WHITE)

DOCB (BLUE)

DOCB (WHITE)

FROMPUMP

FROMPUMP

CABLE #2B

CABLE #3B

CABLE #4B

623

PS1 (BLACK)

1080 1070

543543

TB1B

24V

750−

842

+

_

0V

+

_

WA

GO

I/O

SY

ST

EM

BUS CONTROLLER

MD1B, ETHERNET FIELD−

PS2B

FOOT SWITCH B

PRESSURE SWITCH

RS1B (WHITE) 2 2

INPUT 7 SPARE 1

INPUT 8 SPARE 2

1,IN1

5,IN2

2,IN3

6,IN4

3,IN5

7,IN6

4,IN7

8,IN8

750−

430

RS2B

BIT5B MSB

BIT4B

BIT3B

BIT2B

BIT1B LSB

COLOR CHG W/SUCTION LINE PURGE

SPARE 4

REMOTE PLC INTERFACE

COLOR CHANGE

SELECT & STROBE

RJ−45

MALE

1080 (24VDC,RED)

1070 (24COM,BLACK)

1030 (GND,GREEN/YELLOW)

BLACK

RED

(DESIGNATED INPUTS)

MD3B, 8 PT. SOURCE

VIA ”AUX. 1”

CONTROLPANEL

CONTROLPANEL




721

716

720

719

718

717

715

714

713

712

707

711

710

708

709

706

705

704

703

700

702

701

743

738

742

741

740

739

737

736

735

734

729

733

732

730

731

728

727

726

725

722

724

723

FROM PUMPCABLE #1B

SCCB (BLUE)

SCCB (WHITE)

MD4B, 8 PT. SOURCE

OUTPUT, POS. 2

RM1B (RED)

SPARE(EV12)

P2BE (RED)

C28BE (RED)

C27BE (RED)

C26BE (RED)

C25BE (RED)

P2BE

VALVE

C28BE

VALVE

C27BE

VALVE

C26BE

VALVE

C25BE

VALVE

C28BE (BLACK)

C27BE (BLACK)

C26BE (BLACK)

C25BE (BLACK)

P2BE (BLACK)

1,OUT1

5,OUT2

2,OUT3

6,OUT4

3,OUT5

7,OUT6

4,OUT7

8,OUT8

750−

530

MD5B, 8 PT. SOURCE

OUTPUT, POS. 3

1,OUT1

5,OUT2

2,OUT3

7,OUT6

3,OUT5

6,OUT4

4,OUT7

8,OUT8

750−

530

C24BE (BLACK) C24BE

VALVE

C24BE (RED)

C23BE (BLACK) C23BE

VALVE

C23BE (RED)

C22BE (BLACK)

C21BE (BLACK)

C20BE (BLACK)

C19BE (BLACK)

C18BE (BLACK)

C17BE (BLACK)

C22BE

VALVE

C21BE

VALVE

C20BE

VALVE

C19BE

VALVE

C18BE

VALVE

C17BE

VALVE

C22BE (RED)

C21BE (RED)

C20BE (RED)

C19BE (RED)

C18BE (RED)

C17BE (RED)

MD6B, 8 PT. SOURCE

OUTPUT,POS. 4

C16BE (BLACK)

C15BE (BLACK)

C14BE (BLACK)

C13BE (BLACK)

C12BE (BLACK)

C11BE (BLACK)

C10BE (BLACK)

C9BE (BLACK)

C16BE

VALVE

C15BE

VALVE

C14BE

VALVE

C13BE

VALVE

C12BE

VALVE

C11BE

VALVE

C10BE

VALVE

C9BE

VALVE

C16BE (RED)

C15BE (RED)

C14BE (RED)

C13BE (RED)

C12BE (RED)

C11BE (RED)

C9BE (RED)

C10BE (RED)

1,OUT1

5,OUT2

2,OUT3

6,OUT4

3,OUT5

7,OUT6

4,OUT7

8,OUT8

750−

530

MD7B, 8 PT. SOURCE

OUTPUT, POS. 5

5.OUT2

2,OUT3

1,OUT1

6,OUT4

3,OUT5

7,OUT6

4,OUT7

8,OUT8

750−

530

C7BE (BLACK)

C8BE (BLACK)

C6BE (BLACK)

C5BE (BLACK)

C3BE (BLACK)

C2BE (BLACK)

C1BE (BLACK)

C4BE (BLACK)

C8BE

VALVE

C7BE

VALVE

C6BE

VALVE

C5BE

VALVE

C4BE

VALVE

C3BE

VALVE

C2BE

C1BE

VALVE

VALVE

C7BE (RED)

C8BE (RED)

C6BE (RED)

C5BE (RED)

C4BE (RED)

C3BE (RED)

C2BE (RED)

C1BE (RED)

4. 4.

FLOW CONTROLBOARD B




821

816

820

819

818

817

815

814

813

812

807

811

810

808

809

806

805

804

803

800

802

801

843

838

842

841

840

839

837

836

835

834

829

833

832

830

831

828

827

826

825

822

824

823

MD8B, 8 PT.SOURCE

OUTPUT, POS. 6

1,OUT1

5,OUT2

6,OUT4

3,OUT5

2,OUT3

7,OUT6

4,OUT7

8,OUT8

750−

530

D1BE (BLACK)

D2BE (BLACK)

D1BE

VALVE

D2BE

VALVE

D1BE (RED)

D2BE (RED)

OUTPUT 36 SPARE 2

OUTPUT 37 SPARE 3

OUTPUT 38 SPARE 4

OUTPUT 39 SPARE 5

VFD HIGH SPEED

MD9B,BUS END

POS. 7

1

5

2

6

3

7

4

8

750−

600

4.

P1BE (BLACK) P1BE

VALVE

P1BE (RED)




JUMPER JUMPER

L N GRN

−V +V

VRADJ

DC ON

S8VS12, 24

ON

LINK

TXD/RXD

ERROR

I/O

USR

ERROR

TXD/RXD

LINK

ON

USR

I/O

1 5 1 5 1 5 1 5 1 5 1 5 1 5 1 5

2 6

3 7

4 8

2 6

73

4 8

2 6

73

4 8

2 6

73

4 8

2 6

73

4 8

2 6

73

4 8

2 6

73

4 8

2 6

73

4 8

1 5 1 5 1 5 1 5 1 5 1 5 1 5 1 5

6262626262626262

3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7

8484848484848484

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4 4

3

2

1 1

2

3

4 4

3

2

1 1

2

3

4 4

3

2

1 1

2

3

4 4

3

2

1 1

2

3

4 4

3

2

1 1

2

3

4

WA

GO−

I/O

SY

ST

EM

750−

842

WA

GO−

I/O

SY

ST

EM

750−

842

750−430 750−430 750−530 750−530 750−530 750−530 750−530 750−600 750−600750−530750−530750−530750−530750−530750−430750−430

MD2A

MD3A

MD4A MD6A

MD5A MD7A

MD8A

MD9A MD9B

MD8B

MD7BMD5B

MD6BMD4B

MD3B

MD2B

TB12A

TB11A

TB10A

TB9A

TB8A

TB7A

TB6A

TB1ATB2A

TB3A

TB4A

TB5A

EC1A

TB6B

TB7B

TB8B

TB9B

TB10B

TB11B

TB12B

TB5B

TB4B

TB3B

TB2B

DIN RAIL

LAYOUT DIAGRAM PLC A AND B

PLC ”A” PLC ”B”

4

3

2

1

TB1BEB1

MD1A MD1B

EB2

POWERSUPPLY

2

EC2BCR1




SPARE 1A SPARE 2A SPARE 3A SPARE 4A SPARE 5A SPARE 6A

SPARE 3A SPARE 4A

SPARE 1A SPARE 2A

SPARE 1B SPARE 2B SPARE 3B SPARE 4B

SPARE 1B

SPARE 3B

SPARE 5B SPARE 6B

SPARE 4B

SPARE 2B

LAYOUT DIAGRAM PLC A AND B

22 66 22 66 22 66 22 66 22 66 22 66 22 66 22 66

55115511551155115511551155115511

66226622662266226622662266226622

55115511551155115511551155115511

I/OI/O

USRUSR

ONON

LINKLINK

TXD/RXDTXD/RXD

ERRORERROR

USRUSR

I/OI/O

ERRORERROR

TXD/RXDTXD/RXD

LINK

ON

PLC A LED DEFINITIONSPLC A LED DEFINITIONS PLC B LED DEFINITIONS

PS1A

CCSA

SW1A RS1A

CVBA

DOCA

RS2A

BIT4A

BIT2A BIT1A

BIT3A

BIT5A RM1ASCCA

CCDA P2AE

C27AEC28AE

C25AEC26AE

C24AE

C22AE

C20AE

C18AE C17AE

C19AE

C21AE

C23AE C16AE

C14AE

C12AE

C10AE C9AE

C11AE

C13AE

C15AE C8AE

C6AE

C4AE

C2AE C1AE

C3AE

C5AE

C7AE D2AED1AE

MD2A MD3A MD4A MD6AMD5A MD7A MD8A MD9A

COLOR−ON−DEMAND CONTROLS PLC LABELS

MD9BMD8BMD7BMD5B MD6BMD4BMD3BMD2B

SW1B

CCSB

PS1B DOCB

CVBB

RS1B RS2B

BIT4B

BIT2B BIT1B

BIT3B

BIT5B SCCB

CCDB

C28BE

C26BE C25BE

C27BE

P2BE

RM1B C24BE

C22BE

C20BE

C18BE C17BE

C19BE

C21BE

C23BE C16BE

C14BE

C12BE

C10BE C9BE

C11BE

C13BE

C15BE C8BE

C6BE

C4BE

C2BE C1BE

C3BE

C5BE

C7BE D1BE D2BE

MD1A MD1B


prodigy color-on-demand system generation iii - 1102101prodigy color-on-demand system generation iii...

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