prodigy® plc gateway generation iii -...
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Prodigy� PLC GatewayGeneration III
Customer Product ManualPart 1102107-02
Issued 12/14
NORDSON CORPORATION AMHERST, OHIO USA
For parts and technical support, call the Finishing Customer Support Center at (800) 433-9319.
This document is subject to change without notice.Check http://emanuals.nordson.com for the latest version.
Part 1102107-02 � 2014 Nordson Corporation
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 2007. 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
Prodigy, HDLV, Color-on-Demand, Nordson, and the Nordson logo areregistered trademarks of Nordson Corporation.
All other trademarks are the property of their respective owners.
Change Record i
Part 1102107-02� 2014 Nordson Corporation
tents
Change Record
Revision Date Change
1102107A 07/10 Manual part number 1102107 replaces 1077102.
1101422 replaces 1076798 for Prodigy PLC Gateway.
1101454 replaces 1083689 for Prodigy PLC Gateway PCA Kit.
Added pattern air range, gun purge, and pump speed settings.
02 12/14 Updated drawings and notes
Change Recordii
Part 1102107-02 � 2014 Nordson Corporation
Table of Contents iii
Part 1102107-02� 2014 Nordson Corporation
Table of ContentsSafety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Qualified Personnel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Regulations and Approvals 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Personal Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fire Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Grounding 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Action in the Event of a Malfunction 3. . . . . . . . . . . . . . . . . . . . .Disposal 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation Modes 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preset Mode 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Analog Mode 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Enclosure Mounting 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Power and Fusing 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .Gateway Circuit Board Jumper and Switch Settings 7. . . . . . . .Preset Mode Connections and Settings 9. . . . . . . . . . . . . . . . . . .
Gateway Connections and Settings 9. . . . . . . . . . . . . . . . . . .Analog Mode Connections and Settings 10. . . . . . . . . . . . . . . . . .
Gateway Connections and Settings 10. . . . . . . . . . . . . . . . . . .Electrostatics 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gateway Wiring and Setting Diagram − Preset Mode 12. . . . . .Gateway Wiring and Setting Diagram − Analog Mode 13. . . . . .Pump Control Board Connections and Settings 14. . . . . . . . . . .Gun Cables 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Prodigy MGI Settings 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power On 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Triggering 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gun Strobe 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Faults 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gateway Replacement Parts 18. . . . . . . . . . . . . . . . . . . . . . . . . . .Gun Cables 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional Enclosure Mounting Kit 19. . . . . . . . . . . . . . . . . . . . . . . .
Enclosure Wiring Diagram 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contentsiv
Part 1102107-02 � 2014 Nordson Corporation
Prodigy� PLC Gateway 1
Part 1102107-02� 2014 Nordson Corporation
Prodigy� PLC Gateway
Safety Read and follow these safety instructions. Task- and equipment-specificwarnings, cautions, and instructions are included in equipmentdocumentation where appropriate.
Make sure all equipment documentation, including these instructions, isaccessible to all persons operating or servicing equipment.
Qualified Personnel Equipment owners are responsible for making sure that Nordson equipmentis installed, operated, and serviced by qualified personnel. Qualifiedpersonnel are those employees or contractors who are trained to safelyperform their assigned tasks. They are familiar with all relevant safety rulesand regulations and are physically capable of performing their assignedtasks.
Intended Use Use of Nordson equipment in ways other than those described in thedocumentation supplied with the equipment may result in injury to personsor damage to property.
Some examples of unintended use of equipment include
� using incompatible materials
� making unauthorized modifications
� removing or bypassing safety guards or interlocks
� using incompatible or damaged parts
� using unapproved auxiliary equipment
� operating equipment in excess of maximum ratings
Regulations and Approvals Make sure all equipment is rated and approved for the environment in whichit is used. Any approvals obtained for Nordson equipment will be voided ifinstructions for installation, operation, and service are not followed.
All phases of equipment installation must comply with all federal, state, andlocal codes.
Prodigy� PLC Gateway2
Part 1102107-02 � 2014 Nordson Corporation
Personal Safety To prevent injury follow these instructions.
� Do not operate or service equipment unless you are qualified.
� Do not operate equipment unless safety guards, doors, or covers areintact and automatic interlocks are operating properly. Do not bypass ordisarm any safety devices.
� Keep clear of moving equipment. Before adjusting or servicing anymoving equipment, shut off the power supply and wait until theequipment comes to a complete stop. Lock out power and secure theequipment to prevent unexpected movement.
� Relieve (bleed off) hydraulic and pneumatic pressure before adjusting orservicing pressurized systems or components. Disconnect, lock out,and tag switches before servicing electrical equipment.
� Obtain and read Material Safety Data Sheets (MSDS) for all materialsused. Follow the manufacturer’s instructions for safe handling and useof materials, and use recommended personal protection devices.
� To prevent injury, be aware of less-obvious dangers in the workplacethat often cannot be completely eliminated, such as hot surfaces, sharpedges, energized electrical circuits, and moving parts that cannot beenclosed or otherwise guarded for practical reasons.
Fire Safety To avoid a fire or explosion, follow these instructions.
� Do not smoke, weld, grind, or use open flames where flammablematerials are being used or stored.
� Provide adequate ventilation to prevent dangerous concentrations ofvolatile materials or vapors. Refer to local codes or your material MSDSfor guidance.
� Do not disconnect live electrical circuits while working with flammablematerials. Shut off power at a disconnect switch first to preventsparking.
� Know where emergency stop buttons, shutoff valves, and fireextinguishers are located. If a fire starts in a spray booth, immediatelyshut off the spray system and exhaust fans.
� Clean, maintain, test, and repair equipment according to the instructionsin your equipment documentation.
� Use only replacement parts that are designed for use with originalequipment. Contact your Nordson representative for parts informationand advice.
Prodigy� PLC Gateway 3
Part 1102107-02� 2014 Nordson Corporation
Grounding
WARNING: Operating faulty electrostatic equipment is hazardous and cancause electrocution, fire, or explosion. Make resistance checks part of yourperiodic maintenance program. If you receive even a slight electrical shockor notice static sparking or arcing, shut down all electrical or electrostaticequipment immediately. Do not restart the equipment until the problem hasbeen identified and corrected.
Grounding inside and around the booth openings must comply with NFPArequirements for Class II Division 1 or 2 Hazardous Locations. Refer toNFPA 33, NFPA 70 (NEC articles 500, 502, and 516), and NFPA 77, latestconditions.
� All electrically conductive objects in the spray areas shall be electricallyconnected to ground with a resistance of not more than 1 megohm asmeasured with an instrument that applies at least 500 volts to the circuitbeing evaluated.
� Equipment to be grounded includes, but is not limited to, the floor of thespray area, operator platforms, hoppers, photoeye supports, andblow-off nozzles. Personnel working in the spray area must begrounded.
� There is a possible ignition potential from the charged human body.Personnel standing on a painted surface, such as an operator platform,or wearing non-conductive shoes, are not grounded. Personnel mustwear shoes with conductive soles or use a ground strap to maintain aconnection to ground when working with or around electrostaticequipment.
� Operators must maintain skin-to-handle contact between their hand andthe gun handle to prevent shocks while operating manual electrostaticspray guns. If gloves must be worn, cut away the palm or fingers, wearelectrically conductive gloves, or wear a grounding strap connected tothe gun handle or other true earth ground.
� Shut off electrostatic power supplies and ground gun electrodes beforemaking adjustments or cleaning powder spray guns.
� Connect all disconnected equipment, ground cables, and wires afterservicing equipment.
Action in the Event of a Malfunction If a system or any equipment in a system malfunctions, shut off the systemimmediately and perform the following steps:
� Disconnect and lock out electrical power. Close pneumatic shutoffvalves and relieve pressures.
� Identify the reason for the malfunction and correct it before restarting theequipment.
Disposal Dispose of equipment and materials used in operation and servicingaccording to local codes.
Prodigy� PLC Gateway4
Part 1102107-02 � 2014 Nordson Corporation
Description The Prodigy� PLC Gateway is the interface between an external controllerand a Prodigy HDLV� pump panel and MGI (Manual Gun Interface). TheProdigy MGI software must be version 2.2 or later. The software allows theMGI to control and trigger a Prodigy automatic powder spray gun and HDLVpump in response to commands from the external controller.
The Gateway is capable of interfacing with two Prodigy MGIs and twoautomatic guns, through the Prodigy Manual System pump panel or theProdigy Manual Color-on-Demand� System pump panel. The Gatewayconverts digital or analog signals from an external controller into ProdigyCAN messages.
Robot Controller or PLCProdigy Spray Gun
InterfaceWiring
Prodigy PLC GatewayEnclosure
AC Power
AC Power
CAN NetworkCable
CAN Network/Power Cable
8−meter Gun Cable(4 meter Extensionavailable)
Prodigy MGI #1w/GatewaySoftware
Prodigy Pump Panel
CAN Network/Power Cable
to MGI #2(if used)
Robot InterfaceSignals
Analog and/orDigital
Figure 1 Typical System Diagram
Prodigy� PLC Gateway 5
Part 1102107-02� 2014 Nordson Corporation
Operation Modes
Preset Mode Preset mode is used to switch between presets, which are sets ofpre-programmed spray parameters. Up to 10 presets can be programmedand stored in the MGI.
Preset Mode operates as follows:
1. The external controller first sends a digital signal corresponding to thedesired preset number (1−10) to the Gateway.
2. When it is time to switch to the new preset, the external controller sendsthe Gateway a gun strobe signal.
3. The Gateway reads the preset number signal, converts it into a CANmessage and sends it to the Prodigy MGI.
4. The MGI now operates the spray gun and pump using the parameters ofthe new preset.
Analog Mode Analog mode is used for direct control of the spray parameters for Preset 1.In analog mode, the external controller sends signals to the Gateway tocontrol:
� Powder flow (0−10 Vdc)
� Pattern air flow (0−10 Vdc)
� Assist air compensation (4−20 mA)
� Electrostatics (0−10 Vdc)
In analog mode, the MGI uses only Preset 1 to control the spray gun andpump. The spray parameters for Preset 1 are changed as needed by theexternal controller.
Analog mode operates as follows:
1. The external controller sends the desired analog signals to the Gateway.
2. When the signals are stable the external controller sends the Gateway agun strobe signal.
3. The Gateway then reads the analog signals at its inputs, converts theminto CAN messages, and sends them to the MGI.
4. The MGI changes the spray parameters for preset 1. The gun andpump now operate with the new parameters.
Prodigy� PLC Gateway6
Part 1102107-02 � 2014 Nordson Corporation
Installation WARNING: Allow only qualified personnel to perform the following tasks.Follow the safety instructions in this document and all other relateddocumentation.
WARNING: Use dust-tight conduit connectors or strain reliefs to routecables into all electrical enclosures. Installation must be done according tocode and care must be taken to maintain the dust-tight integrity of theenclosures.
Enclosure Mounting If mounting the enclosure on a Prodigy Manual System stand use theoptional mounting kit listed on page 19, and drill holes in the stand for themounting kit brackets and fasteners as shown in Figure 2.
If mounting on a wall or panel, use the dimensions shown for the enclosurefeet. Use M8 fasteners as needed.
445 mm(17.5 in.)
368.3 mm14.50 in.
470 mm18.50 in.
470 mm18.50 in.
445 mm(17.5 in.)
2
1
345
3456
Figure 2 Gateway Circuit Board Jumper Settings
1. Mounting kit brackets2. Screws, M8 x 16
3. Lock washers, M84. Flat washers, M8
5. Lock nuts, M86. Screws, M8 x 60
Prodigy� PLC Gateway 7
Part 1102107-02� 2014 Nordson Corporation
Electrical Power and Fusing Refer to the Gateway enclosure wiring diagram on page 20.
The Gateway requires 85−230 Vac, 50−60 Hz, single phase, 21 Va inputpower.
Route the AC power leads through a knockout in the bottom of theenclosure and connect them to the L1, L2 and GND terminals on theterminal block as shown in the following wiring diagrams.
Use a liquid-tight cord grip or conduit connector in the knockout. Theenclosure must be dust-tight.
Gateway Circuit Board Jumper and Switch SettingsSee Figure 3.
Open the Prodigy PLC Gateway enclosure, locate JP11, 12, and 13 on theright side of the circuit board and make the following jumper settings foryour application:
JP11 − Mode of Operation
Preset Mode: Open (no jumper) (factory setting)Analog Mode: Jump Pins 1 and 2
JP12 − Number of Guns
1 Gun: Open (no jumper) (factory setting)2 Guns: Jump Pins 1 and 2
JP13 − Type of System
Standard Manual Gun System: Open (no jumper) (factory setting)Color-on-Demand System: Jump Pins 1 and 2
NOTE: Replacement circuit boards are jumpered and programmed at thefactory for the Prodigy PLC Gateway application. The following diagramshows the default jumper settings for the board. Only jumpers JP11, JP12,and JP13 should be changed to configure the board for the application.
SW4-4 − Pattern Air Range
Open: 0.20−2.0 SCFM (0.34−3.4 SCMH)Closed: 0.20−4.0 SCFM (0.34−6.8 SCMH) (Requires 4.0 SCFM orifice.)
Connectors P4 and P6
P4 and P6 each consist of 18 terminals that are divided into 2 sections, Aand B. Section A is a 12 position terminal and section B is a 6 positionterminal. See Figure 3.
Example: P4−13 is marked as P4B−1 on the gateway power control board(PCB).
Prodigy� PLC Gateway8
Part 1102107-02 � 2014 Nordson Corporation
Gateway Circuit Board Jumper and Switch Settings (contd)
1
1
1
1
1 1 1 1
1 1
1 Gun
JP6
JP7
JP8
JP9
JP11
JP12
JP13
JP14
Preset Mode
JP3 JP2
JP4
JP5
JP10
JP19
JP18 JP17 JP16 JP15
1
1
1
1
1
1
1
1
No Jumper Jumpered
CHANGE ONLY JP11, JP12, AND JP13FOR YOUR APPLICATIONLEAVE ALL OTHER JUMPERS AT FACTORY SETTINGS
NOTE:
DefaultApplication−Specific
SettingsStandard
Analog Mode
COD
1
1
1
2 Gun
JP11
JP12
JP13
OptionalApplication-Specific
Settings
1
JP1
P4 (18−1)
P6 (18−1)
Figure 3 Gateway Circuit Board Jumper Settings
Prodigy� PLC Gateway 9
Part 1102107-02� 2014 Nordson Corporation
Preset Mode Connections and Settings
Gateway Connections and Settings Refer to Table 1 and Figure 4 to make input and output connections to theGateway circuit board. Gun 1 and 2 Alarm are optional connections.
Refer to Table 2 when programming the external controller to select presetnumbers.
See note on page 7.
Table 1 Preset Mode External Interface Connections
Signal Conn. Pins Gateway External Signal Type
Trigger 1 P6 1, 2 Input Output Dry Contacts
Trigger 2 P6 3, 4 Input Output Dry Contacts
Preset Bit 1 P5 1 Input Output Dry Contacts
Preset Bit 2 P5 2 Input Output Dry Contacts
Preset Bit 3 P5 3 Input Output Dry Contacts
Preset Bit 4 P5 4 Input Output Dry Contacts
Gun 1 Strobe P5 5 Input Output Dry Contacts
Gun 2 Strobe P5 6 Input Output Dry Contacts
Gun 1 Purge P6 9, 11 Input Output Dry Contacts
Gun 2 Purge P6 12, 14 Input Output Dry Contacts
Gun 1 Alarm P8 1, 2 Output Input 24 Vdc 250 mA Sinking
Gun 2 Alarm P8 4, 5 Output Input 24 Vdc 250 mA Sinking
Table 2 Preset Mode Preset Inputs
Preset Number P5−1 P5−2 P5−3 P5−4
1 1 0 0 0
2 0 1 0 0
3 1 1 0 0
4 0 0 1 0
5 1 0 1 0
6 0 1 1 0
7 1 1 1 0
8 0 0 0 1
9 1 0 0 1
10 0 1 0 1
1 = Shorted0 = OpenAll P5 references to common.
Prodigy� PLC Gateway10
Part 1102107-02 � 2014 Nordson Corporation
Analog Mode Connections and Settings
Gateway Connections and Settings Refer to Table 3 and Figure 5 to make input and output connections to theGateway circuit board. Gun 1 and 2 Alarm are optional connections.
Refer to Tables 4 and 5 when programming the external controller to setspray parameters.
See note on page 7.
Table 3 Analog Mode Inputs and Outputs
Signal Conn. Pins Gateway Robot Signal Type
Trigger 1 P6 1, 2 Input Output Dry Contacts
Trigger 2 P6 3, 4 Input Output Dry Contacts
AFC Mode P6 6, 7 Input Output Dry Contacts
Select Charge Bit 1 P5 1 Input Output Dry Contacts
Select Charge Bit 2 P5 2 Input Output Dry Contacts
Select Charge Bit 3 P5 3 Input Output Dry Contacts
Gun 1 Strobe P5 5 Input Output Dry Contacts
Gun 2 Strobe P5 6 Input Output Dry Contacts
Gun 1 Purge P6 9, 11 Input Output Dry Contacts
Gun 2 Purge P6 12, 14 Input Output Dry Contacts
Gun 1 Alarm P8 1, 2 Output Input 24 Vdc 250 mA Sinking
Gun 2 Alarm P8 4, 5 Output Input 24 Vdc 250 mA Sinking
Pump 1 Speed P5 7 Input Output Dry Contacts
Pump 2 Speed P5 8 Input Output Dry Contacts
Table 4 Analog Mode Spray Parameter Signals
Parameter Conn. Pins Low Scale
kV P4 9, 10 (common) 0−1 V = 0 kV 1−10 V = 25−95 kV
A (AFC) P4 11, 12 (common) 0−1 V = 10 A 1−10 V = 10−100 A
Powder Flow P4 13, 14 (common) − 0−10 V = 0−100%
Pattern Air Flow P4 15, 16 (common) 0−1 V = 0.2 SCFM 1−10V = 0.2−2.0 SCFM
Assist Air Compensation P4 8, 7 (common) 0−3.9mA = 0% 4−20 mA = −50% to +50%
SW4-4 − Pattern Air Range
Open: 0.20−2.0 SCFM (0.34−3.4 SCMH)Closed: 0.20−4.0 SCFM (0.34−6.8 SCMH) (Requires 4.0 SCFM orifice.)
Prodigy� PLC Gateway 11
Part 1102107-02� 2014 Nordson Corporation
Electrostatics Only one electrostatic charging mode can be used at a time: kV mode, Amode (AFC mode), or pre-programmed Select Charge mode.
Refer to the Prodigy Manual Gun Controller manual (P/N1054580) forinformation on electrostatic settings.
kV Mode: This mode is the default mode. kV output is controlled byapplying 1−10 Vdc to connector P4 pins 9 and 10.
AFC Mode: This mode controls current draw (A) instead of kV output. Toplace the MGI in AFC mode, connector P6 pins 6 and 7 must be shorted.Applying 1−10 Vdc to connector P4 pins 11 and 12 then sets the currentdraw limit.
Select Charge Mode: This mode consists of 4 pre-programmedelectrostatic settings. To set a Select Charge mode, place the MGI in AFCmode, then send signals to select the mode according to Table 5.
Table 5 Select Charge Mode Signals
Coating Mode P5−1 P5−2 P5−3
1 − Recoat 1 0 0
2 − Special 0 1 0
3 − Deep Cavity 1 1 0
4 − User Programmable 0 0 1
1 = Shorted0 = OpenAll P5 references to common (P5 pins 9 to 12).
Prodigy� PLC Gateway12
Part 1102107-02 � 2014 Nordson Corporation
Gateway Wiring and Setting Diagram − Preset Mode
P8
123456
1 2 3
P5
123456789101112
P6
123456789101112131415161718
123
P3
123
Drain
Alarm Gun 2
Gun Strobe 1
Trigger Gun 2
Preset Bit 1Preset Bit 2
Gun Strobe 2
Drain
Preset Bit 4Preset Bit 3
Trigger Gun 1
Alarm Gun 1
Optional
GNDL1 L2
Use at least 22 AWGshielded 300Vmulticonductor cable
External Controller Prodigy PLC Gateway
Use 24 AWG TwistedPair with Shield 2conductor300 volt ratingBelden 9841Maximum Length 100M
Main PowerInput TB
For specific wiring details referto controller documentation.
OP
EN
4
3
2
1
SW3
SW1
SW2
1
P5CAN OUT W1
1
Power
Set SW1 and SW2to Position 1
Set SW3−1 to Closed to terminate CAN network,if neccesary
0
23
45678
9
1
0
23
45678
9
1 2 3
P6CAN IN
Drain
REFER TO FIGURE 6 FOR CONNECTIONSTO PUMP CONTROL BOARD, MGI, AND GUN
JUMP PINS 2 AND 3FOR ALL SYSTEM TYPES
85−230 Vac
+−
+−
Purge
Purge
Gun 1
Gun 2
White (Hi)
Blue (Low)
Whi
te
Blu
e
Whi
te
Blu
e
Note: DIP switchSW3−1 is shownhere in the Closedposition.
Figure 4 Gateway Wiring and Setting Diagram − Preset Mode
Prodigy� PLC Gateway 13
Part 1102107-02� 2014 Nordson Corporation
Gateway Wiring and Setting Diagram − Analog Mode
P8
123456
P6
123456789101112131415161718
P3
123
P4
123456789101112131415161718
P5
123456789101112
123
+
Alarm Gun 1
Alarm Gun 2
0−10V DC
−
Pattern Air
+0−10V DC
Select Charge Mode Bit 2
Powder Flow
kV
Gun Strobe 2
AFC ON/OFF
Trigger Gun 2
0−10V DC
Drain
Gun Strobe 1
Drain
+
Select Charge Mode Bit 3
−
−
Select Charge Mode Bit 1
Trigger Gun 1
uA
4−20 mA
L1 L2 GND
External Controller Prodigy PLC Gateway
Use at least 22 AWGshielded 300Vmulticonductor cable
For specific wiring detailsrefer to controllerdocumentation
Main PowerInput TBOptional
SW1
SW2
Set SW1 and SW2to Position 1
Set SW3−1 to Closedto terminateCAN network,if necessary
Power
1 2 3
Drain
Use 24 AWG Twisted Pairwith Shield 2 conductor300 volt ratingBelden 9841Maximum Length 100M
P5CAN OUT
1 2 3
P6CAN IN
Drain
W1
1
Whi
te
Blu
e
Whi
te
Blu
e
NOTE 1
White (Hi)
Blue (Low)
JUMP PINS 2 AND 3FOR ALL SYSTEM TYPES
1
0
23
45678
9
1
0
23
45678
9
REFER TO FIGURE 6 FOR CONNECTIONSTO PUMP CONTROL BOARD, MGI, AND GUN
+0−10V DC −
Assist Air Comp.
85−230 Vac
+
+−
+−
Pump Speed 2Pump Speed 1
Purge
Purge
Gun 1
Gun 2
P5-7 P5-8
Normal
Fast-1
Fast-2
Fast-3
0
1
1
0
0
0
1
1
Pump Speeds
OP
EN
4
3
2
1
SW3
Note: DIP switchSW3−1 is shownhere in the Closedposition.
Figure 5 Gateway Wiring and Setting Diagram − Analog Mode
Prodigy� PLC Gateway14
Part 1102107-02 � 2014 Nordson Corporation
Pump Control Board Connections and Settings
1 2 3
Prodigy Pump Control Board
P5CAN OUT
1 2 3
P6CAN IN W1
1
From Prodigy Gateway FIgure 4 or 5
Single Gun for Standard or Color-on-Demand (COD) Systems
1 2 3
Prodigy Pump Control Board
P5CAN OUT
1 2 3
P6CAN IN W1
1
From Prodigy Gateway FIgure 4 or 5
Dual Gun Standard Systems
Dual Gun Color-on-Demand Systems
1 2 3
Prodigy Pump Control Board(TOP BOARD)
P5CAN OUT
1 2 3
P6CAN IN W1
1
From Prodigy Gateway FIgure 4 or 5
1 2 3
Prodigy Pump Control Board(BOTTOM BOARD)
P5CAN OUT
1 2 3
P6CAN IN W1
1
1
0
23
45678
9
B
A
Set SW1 toPosition 2
Prodigy MGIw/Version 2.2 or
later software
8-meter Gun Cable
Prodigy Gun
Prodigy MGIw/Version 2.2 or
later softwareProdigy Gun
Set GUN NO to 3,GUN TYPE to EXTERNAL−COD
Set GUN NO to 1,GUN TYPE to EXTERNAL−COD
Prodigy MGIw/version 2.2 orlater software
Set GUN NO to 1,GUN TYPE toEXTERNAL (Standard)or EXTERNAL−COD
8-meter Gun Cable
8-meter Gun Cable
Prodigy MGI
Set GUN NO to 1,GUN TYPE toEXTERNAL(Standard)8-meter
Gun CableP/N 1076762
Prodigy MGIw/Version 2.2 or
later software
8-meterGun Cable
Set GUN NO to 2,GUN TYPE to EXTERNAL(Standard)
Prodigy GunProdigy Gun
1
0
23
456789
1 22 3 4SW2
OPEN
1 22 3 4SW2
OPEN
1 22 3 4SW2
OPEN
Set SW1 toPosition 1
1 22 3 4SW2
OPEN
1
0
23
456789
Set SW1 toPosition 1
1
0
23
456789
Set SW1 toPosition 1
Note:SW2-2 is shown in theClosed position (CODenabled).SW2-2 is open forSTD, closed for COD.
Figure 6 Pump Control Board Connections and Settings (1 of 2)
Prodigy� PLC Gateway 15
Part 1102107-02� 2014 Nordson Corporation
Dual Gun on Dual Robot Configuration
Note: Trigger 1and trigger 2 areconnected to bothGateways.
Figure 7 Pump Control Board Connections and Settings (2 of 2)
Prodigy� PLC Gateway16
Part 1102107-02 � 2014 Nordson Corporation
Gun Cables For this application, you cannot use the standard automatic gun cableslisted in the Prodigy Automatic Gun manual. Use the gun cables listed onpage 18.
Prodigy MGI Settings Refer to the Prodigy Manual Gun Controller manual (P/N 1054580) forinformation on preset and configuration settings.
1. If you are using Preset Mode, turn on the MGI and program each of thepresets with the desired values.
2. For both Preset Mode and Analog mode, cycle power while pressing theNordson key. The Configuration menu appears after the MGI boots up.
3. Select SETUP and set the GUN NO (gun number).
� For Standard Systems, set the gun number to 1 or 2, depending onthe number of guns and the gun connected to the MGI.
� For Color-on-Demand Single Gun Systems, set the GUN NO to 1.
� For Color-on-Demand Dual Gun Systems, set the MGI connected topump control board A (bottom board) to GUN NO 1, and the MGIconnected to pump control board B (top board) to GUN NO 3.
4. Set the GUN TYPE:
� For standard systems set to EXTERNALFor Color-on-Demand systems set to EXTERNAL−COD
Setting the gun type to EXTERNAL or EXTERNAL−COD locks the MGIoperator interface so no changes can be made while the externalcontroller is in control. Errors can still be viewed and cleared.
Prodigy� PLC Gateway 17
Part 1102107-02� 2014 Nordson Corporation
Operation Power On
When the Gateway is powered on, it reads the JP11, JP12, and JP13positions for mode of operation, number of guns, and type of system. Itthen sends WHO messages to find the nodes (MGIs) connected to thenetwork. The Green Power LED on the Gateway card blinks at 1 secondintervals.
Triggering When a Trigger 1 or Trigger 2 signal is received, the Gateway immediatelysends a trigger command to the MGI. No Gun Strobe signal is required.The MGI turns on the HDLV powder pump and the spray gun. The spraygun and pump will remain triggered on as long as the signal is present atthe Trigger inputs.
Gun Strobe The Gun Strobe signal tells the Gateway that the data on its inputs is stableand ready to be read. If Gun 1 Strobe is activated the Gateway reads theinputs, converts them to CAN messages and addresses them for gun 1.Gun 2 Strobe works in the same way.
NOTE: Preset values are not retained when the power to either the PLCGateway or to the MGI is cycled in EXTERNAL (gateway) mode. Thismeans that whenever power is cycled to the MGI or the PLC Gateway, therobot or PLC must send the desired preset bits (or analog values) andstrobe them in before triggering the gun.
Data Read
Gun Strobe
Changing Changing
P5−5 Gun 1or
P5−6 Gun 2
Preset Bit ContactsP5−1 to P5−4
Stable DataPreset Mode
Analog Mode
Data Read
Gun Strobe
Changing Changing
P5−5 Gun 1or
P5−6 Gun 2
Stable VoltageDC Voltage for
kV or A, Flow, Pattern
10V
0V
Figure 8 Gun Strobe
Faults Every 2 seconds the Gateway sends a heartbeat message to the MGInodes over the CAN network. If the MGI does not receive a heartbeatmessage from the Gateway for 15 seconds the MGI will display an E31error code (Gateway heartbeat missing). The MGI nodes also send outheartbeat messages. If the Gateway does not receive a heartbeat messagefrom the MGI nodes for 15 seconds, then a communication fault occurs andthe Red Fault LED is turned on. Refer to Troubleshooting in the ProdigyManual Gun Controller manual for fault codes and suggested corrections.
Prodigy� PLC Gateway18
Part 1102107-02 � 2014 Nordson Corporation
Parts To order parts, call the Nordson Finishing Customer Support Center at (800)433-9319 or contact your local Nordson representative. For moreinformation, go to http://www.nordson.com on the Internet.
Gateway Replacement Parts
Item Part Description Quantity Note− 1101422 GATEWAY, PLC, Prodigy, Generation III 1
1 1101454 � KIT, PCA, Prodigy PLC gateway, Generation III 1
2 288807 � FILTER, line, RFI power 1
3 131477 � FUSE, 2.00, fast-acting, 250 V, 5 x 2 2
4 288803 � POWER SUPPLY, 24, 5, 12 Vdc, 40 W 1
1
2
3 4
Figure 9 Prodigy PLC Gateway Parts
Gun Cables
Part Description Note1076762 CABLE, Prodigy bar mount gun, 8 meter A1073027 CABLE, handgun, 4 meter extension A1083912 CABLE, handgun, 6 meter extension A
NOTE A: The 8-meter cable is a special cable used only for connecting Prodigy automatic guns to Prodigy MGIcontrollers. If using the 4 meter extension, install it in between the 8 meter cable and the MGI.
Prodigy� PLC Gateway 19
Part 1102107-02� 2014 Nordson Corporation
Optional Enclosure Mounting Kit See Figure 2 for kit components. Use this kit to mount the Gatewayenclosure on a Prodigy Manual System stand.
Item Part Description Quantity Note− 1077918 KIT, mounting, Prodigy PLC Gateway 11 - - - - - - � BRACKET, PLC gateway 22 - - - - - - � SCREW, hex, cap, M8x 16, black 43 - - - - - - � WASHER, lock, M8, steel, zinc 84 - - - - - - � WASHER, flat, M8, steel, zinc 85 - - - - - - � NUT, hex, lock, torque, M8 86 - - - - - - � SCREW, hex, cap, M8 x 60, black 4
Prodigy� PLC Gateway20
Part 1102107-02 � 2014 Nordson Corporation
Enclosure Wiring Diagram
MAIN POWER INPOWER CORD
40W
PO
WE
R S
UP
PLY
2888
03
GR
EE
N/Y
ELL
OW
(G
ND
)
BLA
CK
GR
AY
OR
AN
GE
RE
D1
L (3
)
SK
1
N (
1)
BLACK
RED
GND(INSIDE DOOR)
GND(INSIDE ENCLOSURE)
BLU
E
(L2 −
NE
UT
RA
L)
BR
OW
N
(L1 −
HO
T)
BLACK
RED
SK
2
2 3 4 5 6
ORANGE
GRAY
(FIELD INSTALLED)
TERMINAL BLOCK
L1
L2
L1
L2
GND
TERMINALBLOCK
L2L1
L1 L2
BLU
E
(L2 −
NE
UT
RA
L)
GR
EE
N/Y
ELL
OW
(G
ND
)
BR
OW
N
(L1 −
HO
T)
(FIELD INSTALLED)
AUX. POWER OUTPOWER CORD
BR
OW
N
BLU
E
GR
N/Y
EL
BLU
E
BR
OW
N
BLUE
BROWN
LINE FILTERRFI POWER
288807
BR
OW
N
BLU
E
L1
L2
L1
L2
GND
654321
BLACK
REDP7
Power Requirement:85−230 Vac, 50−60 Hz, 1 , 21 VA
3
2
1
CA
N−
L B
LUE
CA
N−
H W
HIT
ET
O C
AN
NE
TW
OR
K
P3
Figure 10 Enclosure Wiring Diagram