1066483A04 Prodigy Color-on-Demand Controller and Control ...

Prodigy� Color-on-Demand�Controller and Control Panel

Customer Product ManualPart 1066483A04

Issued 03/09

NORDSON CORPORATION AMHERST, OHIO USA

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

This document is available on the Internet at http://emanuals.nordson.com/finishing

Nick.Klasovsky

Rectangle

Part 1066483A04 � 2009 Nordson Corporation

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 Operation 4. . . . . . . . . . . . . . . . . . . . . . . . . .

Accumulator Tank Function 4. . . . . . . . . . . . . . .Color Change Manifold 4. . . . . . . . . . . . . . . . . . .

Color-on-Demand Controller Setup and Operation 6.Screen Map 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Color Change without Suction Line Purge 7. . . . .Button Labeling 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .System Cleaning 8. . . . . . . . . . . . . . . . . . . . . . . . . . .Color Change with Suction Line Purge 9. . . . . . . .Valve Counters 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .System Clock 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Software Version 10. . . . . . . . . . . . . . . . . . . . . . . . . . .

Screen Brightness 10. . . . . . . . . . . . . . . . . . . . . . .Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inputs 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Outputs 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Powder Flow 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service Screen 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Parts 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Kit Parts 14. . . . . . . . . . . . . . . . . . . . . . . . .Controller Parts 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Retrofit Kit 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Color Change Control Panel Parts 18. . . . . . . . . . . .Control Unit (PLC) Parts 20. . . . . . . . . . . . . . . . . . . .Ship-With Kit Parts 22. . . . . . . . . . . . . . . . . . . . . . . . .

Diagrams and Schematics 23. . . . . . . . . . . . . . . . . . . .Controller Wiring Diagram 23. . . . . . . . . . . . . . . . . . . .Control Panel Internal Pneumatic Diagram 24. . . . .Control Panel External Pneumatic Diagram 25. . . .Control Panel Wiring Diagram (Sheet 1 of 2) 26. . .Control Panel Wiring Diagram (Sheet 2 of 2) 27. . .Control Panel Schematic (Sheet 1 of 10) 28. . . . . .Control Panel Schematic (Sheet 2 of 10) 29. . . . . .Control Panel Schematic (Sheet 3 of 10) 30. . . . . .Control Panel Schematic (Sheet 4 of 10) 31. . . . . .Control Panel Schematic (Sheet 5 of 10) 32. . . . . .Control Panel Schematic (Sheet 6 of 10) 33. . . . . .Control Panel Schematic (Sheet 7 of 10) 34. . . . . .Control Panel Schematic (Sheet 8 of 10) 35. . . . . .Control Panel Schematic (Sheet 9 of 10) 36. . . . . .Control Panel Schematic (Sheet 10 of 10) 37. . . . .

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 2005. 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

Nordson and the Nordson logo are registered trademarks of NordsonCorporation.

Prodigy and Color-on-Demand are trademarks of Nordson Corporation.

DECLARATION of CONFORMITY

PRODUCT:

Prodigy Color on Demand, HDLV Manual Pump Cabinet and ControlsOne or two gun, manual pump system for use with a Manual Applicator and Controller.

APPLICABLE DIRECTIVES:

98/37/EEC (Machinery)2006/95/EC (Low–Voltage Directive)2004/108/EEC (Elecromagnetic Compatibility Directive)

STANDARDS USED TO VERIFY COMPLIANCE:

IEC60417 EN61000–6–2EN12100 EN55011EN60204 EN61000–6–3NFPA79

PRINCIPLES:

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

Quality Certificate:

DNV ISO9001:2000

Date: 15 October 2007

Joseph SchroederEngineering Manager, Finishing Product Development Group

Nordson Corporation � Westlake, Ohio DOC14019A02

Color-on-Demand� Controller and Control Panel 1

Part 1066483A04� 2009 Nordson Corporation

Color-on-Demand� Controller and Control Panel

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

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

Qualified Personnel

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

Intended Use

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

Some examples of unintended use of equipmentinclude

� using incompatible materials

� making unauthorized modifications

� removing or bypassing safety guards orinterlocks

� using incompatible or damaged parts

� using unapproved auxiliary equipment

� operating equipment in excess of maximumratings

Regulations and Approvals

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

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

Personal Safety

To prevent injury follow these instructions.

� Do not operate or service equipment unless youare qualified.

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

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

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

Color-on-Demand� Controller and Control Panel2


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

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

Fire Safety

To avoid a fire or explosion, follow theseinstructions.

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

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

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

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

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

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

Grounding

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

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

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

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

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

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

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

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

Action in the Event of a Malfunction

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

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

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

Disposal

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



Description This manual covers the Color-on-DemandController and Control Panel.

For operation instructions, refer to theColor-on-Demand Operator Card.

Detailed maintenance and repair instructions andparts lists for other components of the system arecontained within their manuals.

Color-on-Demand Controller

Color-Control Panel

HDLV PumpPump Manifold and PCB

Pump Control Panel

Dump Valveand Color Change Manifold

Manual Gun ControllerProdigy Manual Gun

Figure 1 Color-on-Demand System Components and Manuals



System Operation

Air and power are supplied to the color controlpanel from the pump control panel.

AGun

Gun B

ManifoldPurgeValves

PLC

FootpedalPressure

Switch

SolenoidValves

SystemPressure

Switch

PumpControlBoards

AccumulatorTank

CO

LOR

CO

NT

RO

L P

AN

EL

PU

MP

PA

NE

L

Figure 2 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.

NOTE: Refer to the Prodigy� Color-on-DemandSystem manual for instruction on wiring theethernet 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.

Accumulator Tank Function

The accumulator tank bolted to the bottom of thepanel stand contains an emergency supply ofcompressed air to keep the color change manifoldvalve bladders inflated if air pressure to the systemis lost while there is powder in the system. If airpressure is lost and the bladders deflate, some ofthe powder may migrate into the other color valves.

Cleaning the system after a loss of air pressure iscovered in the Maintenance section of this manual.

Color Change Manifold

The color change manifold consists of 3 valveblocks with 10 ports in the side of each block andports at each end. Of the 30 side ports, 28 arepowder inlet valves, one is a purge air inlet valveand one is a dump outlet valve (Dump 1) to thebooth. A separate external dump valve (Dump 2) 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 1 and Dump 2 valves, allowing them to openso that purge air can push the remaining powder inthe suction lines and manifold out through thedump lines to the 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 ProdigyManual Spray Gun Controller (manual 1054580) fora description of the color change cycle andsettings.



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 2Dump 1

Suction Line to Pump

Dump

Dump 2Valve

Manifold A B

Manifold(End View)

Panel Stand(Rear View, with Cover Removed)

Dump 2 Valve(Side View)

Pinch Bladder

Bladders

Dump 2 Valve

Figure 3 Color Change Manifold and Dump Valve



Color-on-Demand Controller Setup and Operation 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 4 Color-on-Demand Controller Screen Map



Color Change without Suction LinePurge

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 5 Splash Screen

Touch the Splash screen to open the Main screen.

Figure 6 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 7 Small Buttons Screen

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

Figure 8 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 footpedal 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 9 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 10 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.

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 11 Purge Screen



Color Change with Suction Line Purge

NOTE: To perform this procedure the HopperPurge and Hopper Mode fuctions must be enabled.See the Service Screen section on page 13 toenable and disable the functions.

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

Touch the button for Suction Line Selection todisplay option between Current Suction Line orNext Suction Line. If the desired suction line is notdisplayed, touch the button again to toggle to theother selection.

After selecting the correct suction line, touch theStart button to begin the suction line purge. Thewords In Process will flash on screen while systemis 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 12 Screen display for CURRENT suction linepurge

Figure 13 Screen display for NEXT suction line purge

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 12 for more information on this screen.

Figure 14 Valve Counter Screen



System Clock

See Figure 15. To set the system clock, go to the Test screen, then touch the Set Clock button.

Software Version

See Figure 15. Go to the Test screen, then touch Software Version. This screen displays software versioninformation. You may be asked for this information if you call for technical support.

Screen Brightness

After selecting the Software Version option, touch the arrow buttons to adjust the brightness of the displayscreen.

Troubleshooting WARNING: Allow only qualifiedpersonnel to perform the following tasks.Follow the safety instructions in thisdocument and all other relateddocumentation.

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 15 Test Screen

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

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 16 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 theLEDs on the PLC output modules and on thecorresponding solenoid valves, and send an airsignal to the appropriate valve bladder.

Figure 17 Outputs 1−20 Screen Figure 18 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

35−40 SPR1−6 Spares

Powder Flow

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

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



Service Screen

The Service screen is used by Nordson CSRs.

Figure 19 Service Screen

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.Hopper Mode: Enables/Disables ability foroperator to select the suction line to be purgedbetween current or next suction line from theconfirmation screen.

Repair

WARNING: Before making repairs to any component of the system, disconnect and lockoutpower at the system disconnect. Shut off the system air supply at the ball valve on the pumppanel and release the air in the accumulator tank.

Repair of the Color-on-Demand controller and colorcontrol panel is limited to replacement ofcomponents. Refer to to the foldouts in the back ofthis manual for pneumatic and electrical diagrams.

Refer to the parts lists in this manual forreplacement parts for the controller and controlpanel, and . Manifold and dump valve parts arelisted in manual 1066484 for Generation II systems.



Parts

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

Controller Kit Parts

See Figure 20.

Item Part Description Quantity Note— 1084554 KIT, controller interface, Prodigy color change 1

1 1084529 � CONTROLLER interface, Prodigy color change 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

control1

NOTE A: See Figure 20 and accompanying parts list for serviceable parts.



2

7

45

8

9

1

10

11

3

6

12

Figure 20 Controller Kit Parts



Controller Parts

See Figure 21.

Item Part Description Quantity Note— 1084529 CONTROLLER, interface, Prodigy color change 1

1 1084403 � TERMINAL, display, COD Generation II 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 1084551 to replace Cimrex 69 display terminal with the Proface AGP3300 display

terminal.

Retrofit Kit

Item Part Description Quantity Note— 1084551 KIT, retrofit, display, COD Generation II 1

1 1084403 � TERMINAL, display, COD, Generation II 111 - - - - - - � PLATE, adapter with studs 112 - - - - - - � GASKET, adapter plate 113 - - - - - - � PLATE, adapter 114 983102 � WASHER, lock, E, SPT, #6, steel, zinc,

14451−CA4

15 984101 � NUT, hex, machine, #6−32, steel, zinc,14441−CA

4



2

1

3

4

53

67

89

9

10

7

6

1112

13

14

15

Figure 21 Controller Parts



Color Change Control Panel Parts

See Figure 22.

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

changer1

1 1084550 � CONTROL UNIT, dual pump color changer,PLC

1 A

2 1084489 � 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.

B: One required per gun.

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

D: 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 22 Color Control Panel Parts



Control Unit (PLC) Parts

See Figure 23.

Item Part Description Quantity Note− 1084550 CONTROL UNIT, dual pump color changer, PLC 1

− 1084489 CONTROL UNIT, single pump color changer, PLC 1

1 1106849 � CONTROLLER, programmed, CODGeneration II

AR A, D

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

AR B, D

3 1064195 � MODULE, 8-channel digital input, 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

Figure 23 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 A

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 A972141 � 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-on-Demand Controls 23


5 6

32

ENCLOSURE1064409

ADAPTER PLATE1083016

ETHERNET CABLE1072866

(FIELD INSTALLED)

PART OF1065029

GROUND WIRE302189

RECEPTACLE 6 PIN1065029 ROCKER SWITCH

322404

FROM ETHERNET INSULATIONDISPLACEMENT CONNECTOR1067145 (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

324343

TO BACK PLATEGROUND STUD

YELLOW

WHITE

GREEN

BLACK

GRAY

(ENCLOSURE GROUND) (ENCLOSURE GROUND)

USB

COM 1

COM 2

LANRJ−45

CONNECTOR

Pro−faceAPG3300−T1−D24P/N 1084403

5 6

32

Figure 24 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

AIR

TA

NK

BU

LKH

EA

D

C

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 25 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 26 Color Change Control Panel External Pneumatic Diagram (Dual Unit Shown)



XXXPEXXXXX

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)

TO: PRODIGYDUAL PUMP

CONTROL PANELB

TO: PRODIGYDUAL PUMP

CONTROL PANELA

PRODIGY COLOR CHANGESUB PANEL

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 CONTROL PANEL)

BRN

GRNGRN/WHT

BRN/WHT

BLUORG/WHTORG

BLU/WHT

DETAIL B

SEE DETAIL B

ETHERNET INSULATIONDISPLACEMENT CONNECTORMODULE 1067145(FIELD INSTALL)

ETHERNET CONNECTORMODULE MOUNTING BOX1067146 (FIELD INSTALL)

100 FT. ETHERNET PATCH CABLE 1058222TO BE PULLED THRU CONDUIT TO PRODIGYCOLOR CHG CONTROLLER INTERFACE 1064954(FIELD INSTALL − TRIM TO LENGTH)

FIELD INSTALLATION

PRESSURE SWITCH(70 PSI)

Figure 27 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

PRODIGYDUAL PUMPCONTROLLER

1047464

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

TO

: P1B

EB

LAC

KR

ED

BLUEWHITE

BLACK+24VDC RED

RED

BLACK

(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 CONTROL 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

BLACK

WHITEBLUE

RED

TO: PLC A(SEE SCHEMATIC)

CA

BLE

#2A

CA

BLE

#1A

TO

: P1A

E

(BLU

E)

(BLU

E)

(WH

ITE

)

(WH

ITE

)

BLA

CK

RE

D

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

WAGO MD2−7, IN6TB5−2, 24COM




CO

LOR

CH

AN

GE

PA

NE

L

TB

6−2,

24C

OM

WA

GO

MD

2−2,

IN3

TB

6−2,

24C

OM

WA

GO

MD

4−1,

OU

T1

TB

6−2,

24C

OM

WA

GO

MD

2−2,

IN3

TB

6−2,

24C

OM

WA

GO

MD

4−1,

OU

T1

SC

C

CC

S

SW1

OPEN

21 43SW2

1

SC

C

CC

S

Figure 28 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

Figure 29 Color-on-Demand Control Panel Schematic (Dual Unit, Sheet 1 of 10)



221

216

220

219

218

217

215

214

213

212

207

211

210

208

209

206

205

204

203

200

202

201

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

SPARE 3

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 35 SPARE 1

OUTPUT 36 SPARE 2

OUTPUT 37 SPARE 3

OUTPUT 38 SPARE 4

OUTPUT 39 SPARE 5

OUTPUT 40 SPARE 6

MD9A,BUS END

POS. 7

1

5

2

6

3

7

4

8

750−

600

4.




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




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

SPARE 3

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 35 SPARE 1

OUTPUT 36 SPARE 2

OUTPUT 37 SPARE 3

OUTPUT 38 SPARE 4

OUTPUT 39 SPARE 5

OUTPUT 40 SPARE 6

MD9B,BUS END

POS. 7

1

5

2

6

3

7

4

8

750−

600

4.




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


1066483A04 Prodigy Color-on-Demand Controller and Control ...

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Transcript of 1066483A04 Prodigy Color-on-Demand Controller and Control ...