Nordson Prodigy Customer Product Manual
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Nordson Prodigy Customer Product Manual

Automatic powder spray guns
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Prodigy
Automatic Powder
Spray Guns
Customer Product Manual
Part 1054075B07
Issued 9/10
For parts and technical support, call the Industrial Coating
Systems 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.
FM
C
US
APPROVED
NORDSON CORPORATION  AMHERST, OHIO  USA

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Summary of Contents for Nordson Prodigy

  • Page 1 For parts and technical support, call the Industrial Coating Systems 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. APPROVED NORDSON CORPORATION  AMHERST, OHIO  USA...

  • Page 2: Table Of Contents

    ......Contact Us Notice This is a Nordson Corporation publication which is protected by copyright. Nordson Corporation welcomes requests for information, comments, and Original copyright date 2004. No part of this document may be inquiries about its products.

  • Page 3: Safety

    Make sure all equipment is rated and approved for operating or servicing equipment. the environment in which it is used. Any approvals obtained for Nordson equipment will be voided if instructions for installation, operation, and service Qualified Personnel are not followed.

  • Page 4: Fire Safety

    Use only replacement parts that are designed cables, and wires after servicing equipment. for use with original equipment. Contact your Nordson representative for parts information and advice. Action in the Event of a Malfunction If a system or any equipment in a system...

  • Page 5: Description

    ® Prodigy Automatic Powder Spray Guns Description Features The Prodigy Automatic Powder Spray Guns use specially designed flat-spray and conical nozzles to • Standard 8-mm poly tubing for powder delivery atomize, shape, and spray dense-phase powder • delivered by Nordson HDLV® (high-density powder, Nozzle and internal powder tube are the only low-volume air) pumps.

  • Page 6: Tube-Mount Gun Components

    * Voltage Multiplier Heat Sink Bracket Multiplier Harness Gasket Air Tubing Connectors Heat Sink Control Cable Receptacle Lock Knob (Powder Tubing Tubing Grip Ring Figure 2 Section View − Tube Mount Gun Components and Assembly Part 1054075B07 © 2010 Nordson Corporation...

  • Page 7: Bar-Mount Gun Components

    Air Tubing Connectors 5/8 in. Bar (Optional) Lock Nut Cable Receptacle Lock Knob 1-1/4 in. OD, (Powder Tubing) 0.188 in. wall Tube Tubing (Optional) Grip Ring Figure 3 Section View − Bar-Mount Gun Components and Assembly Part 1054075B07 © 2010 Nordson Corporation...

  • Page 8: Specifications

    6.9 bar (100 psi). 1575.9 mm 62.00 in. 38.8 mm (1.53 in.) 80 mm 3.15 in. 485.9 mm 38.8 mm (19.13 in.) (1.53 in.) 48 mm 137.7 mm (1.89 in.) (5.42 in.) Figure 4 Gun Dimensions Part 1054075B07 © 2010 Nordson Corporation...

  • Page 9: Installation

    1.25-in. O.D. 3. To pivot the gun vertically on the clamp, loosen tubes the socket screw. Refer to page 29 for the gun bar assemblies. Also available for the bar-mount gun is an ion collector. Part 1054075B07 © 2010 Nordson Corporation...

  • Page 10: Optional Ion Collector For Bar-Mount Guns

    2. Install the ion collectors. approximately 25 mm (1-in.) and test again. 3. Start coating parts again. Slide the collector rod forward until the current draw is 5 to 7 A higher than without the kit. Part 1054075B07 © 2010 Nordson Corporation...

  • Page 11: Tubing And Cable Connections

    Tubing and Cable Connections Operation All automatic gun functions are set and controlled by the Prodigy iControl Integrated Control System. Refer to the iControl Operator Interface manual 1056418 for instructions on making spray settings. WARNING: This equipment can be dangerous unless it is used in accordance with the rules laid down in this manual.

  • Page 12: Maintenance

    Rinse and blow off with compressed air. If desired, remove the nozzle nut from the nozzle by sliding the nut forward then turning it clockwise to unscrew it. Figure 10 Nozzle Disassembly Step 2A Part 1054075B07 © 2010 Nordson Corporation...
  • Page 13 Note: All internal components, except the electrodes, are the same for all nozzles. For flat-spray, cross, and pinpoint nozzles, the electrode is glued into the nozzle shell with epoxy and cannot be replaced separately. Part 1054075B07 © 2010 Nordson Corporation...

  • Page 14: Troubleshooting

    If you cannot solve the problem with the information given here, Follow the safety instructions in this contact your local Nordson representative or the document and all other related Nordson Finishing Customer Support Center at documentation.

  • Page 15: Continuity And Resistance Tests

    Figure 15 Multiplier/Resistor Test Resistor Test − All Versions Remove the resistor as described in Resistor Replacement on page 16. Resistor reading should be 153−187 megohms. 153−187 MQ Figure 16 Resistor Test Part 1054075B07 © 2010 Nordson Corporation...

  • Page 16: Multiplier/Contact Test − Bar-Mount Only

    Test from the shorting plug or shorted pins to the 15−24 MQ brass contact inside the multiplier well. Resistance should read 140−200 megohms. Figure 19 Contact Test − Bar Mount Only 140−200 MQ Figure 18 All Versions − Multiplier Test Part 1054075B07 © 2010 Nordson Corporation...

  • Page 17: Control Cable Continuity Test

    +VDC J1−3 J2−3 A FDBK A FDBK J1−4 J2−4 EMPTY BLANK (N/C) J2−5 J1−5 CHASSIS GND J2−6 SPIRAL WRAPPED SHIELD J1−6 (GUN ID) J1−7 499Q (GUN ID) J1−8 Figure 20 Control Cable Continuity Tests Part 1054075B07 © 2010 Nordson Corporation...

  • Page 18: Repair

    5. See Figure 24. Remove the two screws (22) with a 2.5 mm hex wrench, then unscrew the lock nut (18). Figure 25 Pulling the Heat Sink away from the Housing Part 1054075B07 © 2010 Nordson Corporation...

  • Page 19: Resistor Installation

    (18) until it bottoms out, then tighten bottoms out. Rotating the resistor helps release the lock knob (20). trapped air pockets from the grease. Clean off any excess grease. 12. Reconnect the air tubing and control cable. Part 1054075B07 © 2010 Nordson Corporation...

  • Page 20: Multiplier Replacement

    (24C), pad, and washer. includes a new bracket (24C), pad, and washer. Part 1054075B07 © 2010 Nordson Corporation...

  • Page 21: Multiplier Installation

    Figure 34 Multiplier Well Greasing − Tube-Mount Gun Tube-Mount Gun Cable Guide (8) Electrode Cable (10) Bar-Mount Gun Sleeve (8) Powder Tube (5) Contact Guide (10) Multiplier Contact (12A) Figure 35 Multiplier Installation: Step 6 Part 1054075B07 © 2010 Nordson Corporation...

  • Page 22: Electrode Cable Replacement

    4. See Figure 41. Pull the housing (11) off the body tube (9) to expose the cable guide (8). Figure 38 Pulling Heat Sink away from Housing Figure 41 Pulling Housing Off Body Tube Part 1054075B07 © 2010 Nordson Corporation...

  • Page 23: Parts

    (14). 16. Reconnect the air tubing and control cable. Parts To order parts, call the Nordson Industrial Coating Systems Customer Support Center at (800) 433-9319 or contact your local Nordson representative. Parts lists start on the following page.

  • Page 24: Tube-Mount Gun Parts List

    • KIT, nozzle, flat spray, dual slot, converging angle, 1 mm 1054529 • KIT, adapter, Prodigy, spring, auto 1101268 • CLIP, ion collector, 4-probe, Prodigy, packaged 1101304 • • SCREW, pan, recessed, M4 x 6, nylon, black 1101269 • ROD, tube mount ion collector, Prodigy 1101296 •...
  • Page 25 ® Prodigy Automatic Powder Spray Guns Figure 43 Tube-Mount Gun Parts Part 1054075B07 © 2010 Nordson Corporation...

  • Page 26: Bar-Mount Gun Parts List

    See Figure 44. Item Part Description Quantity Note — 1070497 GUN, auto, 95 kV, Prodigy, bar mount 1078850 • NUT, retaining 1073706 • KIT, nozzle, flat spray, dual slot, converging angle, 1 mm 1054529 • KIT, adapter, Prodigy, spring, auto 900742 •...

  • Page 27: Nordson Corporation

    ® Prodigy Automatic Powder Spray Guns Figure 44 Bar-Mount Gun Parts Part 1054075B07 © 2010 Nordson Corporation...

  • Page 28: Service Kits

    APPLICATOR, dielectric grease 161411 PLUG, shorting, IPS 1101301 KIT, ion collector retrofit, bar mount, Prodigy NOTE A: Carton of 12 3-cc dielectric grease applicators. B: Use for testing voltage multiplier/resistor/electrode resistance. C: Refer to page 27 for repair parts for this kit.

  • Page 29: Optional Ion Collector For Bar-Mount Gun

    Optional Ion Collector for Bar-Mount Gun Item Part Description Quantity Note − 1101301 KIT, ion collector retrofit, bar mount, Prodigy 1101291 • BRACKET, ion collector rod, bar mount, Prodigy 983127 • WASHER, lock, internal, M5, zinc 326507 • SCREW, pan head, cross-recessed, M5 x 8 1101290 •...

  • Page 30: Ion Collector Retrofit Kit For Tube-Mount Gun

    Item Part Description Quantity Note − 1101300 KIT, ion collector retrofit, tube mount, Prodigy - - - - - - • JAW ASSEMBLY, fixed, clamp with ground, Prodigy automatic 1101296 • SUPPORT, ion collector, Prodigy, packaged 982067 • • SCREW, set, cup, M5 x 5, black 1101268 •...

  • Page 31: Tube-Mount Gun Clamp

    GUN CLAMP, Prodigy auto - - - - - - • CLAMP, bar, universal - - - - - - • JAW, fixed clamp with ground, Prodigy auto - - - - - - • JAW, floating clamp, Prodigy auto 249074 •...

  • Page 32: Optional 4 Foot Gun Bar Assembly For Bar-Mount Guns

    1073818 • NOZZLE, 40 degree, conical (shell) NOTE A: One of each supplied with spray gun. B: Optional nozzles, not included with spray gun. C: Nozzle shell only. Does not include internal components. Part 1054075B07 © 2010 Nordson Corporation...

  • Page 33: Conical Nozzle Components

    O-RING, silicone, 0.625 x 0.75 x 0.063 in. 1073625 INSERT, metric, conical/flat nozzles 1073624 CONE, porous, nozzle 1062177 ELECTRODE, spring contact, 0.094 dia, Prodigy NOTE A: Also available in quantities of 10. Order kit 1073707. NOZZLE SHELL Refer to Conical Nozzle List for replacement part number...

  • Page 34: Flat Spray, Cross, And Pinpoint Nozzles

    1077385 6−8 inches General use KIT, nozzle, flat spray, Prodigy, 75 degree (152−230 mm) on manual or 1077395 • NOZZLE, shell with electrode, flat spray, Prodigy, automatic 75 degrees guns 1077382 2−4 inches Manual KIT, nozzle, flat spray, Prodigy, 90 degree (51−102 mm)

  • Page 35: Flat Spray, Cross, And Pinpoint Nozzle Components

    • NOZZLE shell with electrode NOTE A: Refer to Nozzle parts list on previous page for part numbers. Also available in quantities of 10. Order kit 1073707. Figure 53 Flat Spray, Cross, and Pinpoint Nozzle Components Part 1054075B07 © 2010 Nordson Corporation...
  • Page 36 ® Prodigy Automatic Powder Spray Guns Part 1054075B07 © 2010 Nordson Corporation...

  • Page 37: Nordson Corporation

    - Ex II (2) 3D T200 _C = (Controllers) Mike Hansinger Date: 22 June 2011 Manager Engineering Development Industrial Coating Systems Nordson Corporation NORDSON AUTHORIZED CONTACT REPRESENTATIVE IN THE EU: Operations Manager Industrial Coating Systems Nordson Deutschland GmbH Heinrich−Hertz−StraBe 42−44 D−40699 Erkrath...

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