E-200 Module Service Kit

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1 Instruction Sheet E-200 Module Service Kit 1. Introduction These instructions describe how to remove and replace the E-200 module. The instructions include the following: S S S S Safety Unit Preparation Module Removal and Replacement Alternate Module Removal and Replacement 2. Safety WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. 3. Unit Preparation Perform the following steps to relieve hydraulic pressure before disassembling and replacing any gun component. WARNING: Risk of burns. Failure to relieve system pressure can result in hot material spraying from a connecting point, possibly causing serious burns. 1. Heat the system to operating temperature. 2. Turn the applicator pumps off.

2 2 E-200 Module Service Kit 3. Unit Preparation (contd.) 3. Place a drain pan under the applicator s filter drain valve. NOTE: Figure 1 shows a typical drain pan placement. Details may vary depending on the applicator model. 4. Follow instructions provided in your applicator s technical manual for relieving system hydraulic pressure. 5. Properly dispose of the drained adhesive. Fig. 1 Typical Drain Pan Placement WARNING: Risk of burns. Shield the area and operator. Failure to perform the next step can result in hot material spraying from a connecting point downstream of the applicator pump. 6. Trigger the gun module(s) from the gun driver to relieve pressure downstream of the pump. 7. Turn off the electric gun driver. 8. Wipe off any adhesive on the gun fittings.

3 E-200 Module Service Kit 3 4. Module Removal and Replacement NOTE: To remove the coil and module assembly with the gun installed at the station, you need a minimum of 3 inches above the coil in order to completely remove the coil from the adapter/pole assembly. If you do not have this minimum clearance or the gun module and coil are badly charred, perform the alternate method of removing or installing the module described in 5. Alternate Module Removal and Replacement Procedure in this document. The alternate procedure requires only 1 inch of clearance above the coil because the coil and module are removed as an assembled unit. 1. Relieve hydraulic pressure as described in 3. Unit Preparation in this document. WARNING: Hot! Risk of burns. Hot applicator parts, splashed adhesive, and hot gun surfaces can cause severe burns. Wear long-sleeved, heat-protective clothing, safety goggles, and heat-protective gloves. WARNING: Risk of electrical shock. Failure to observe may result in personal injury or death. 2. Set the applicator circuit breaker to the OFF position. Fig. 2 Turning Off Applicator Circuit Breaker Disconnect and lock out the input power line to the applicator main circuit breaker. 4. Disconnect and lockout power to the driver Fig. 3 Locking Out Input Power

4 4 E-200 Module Service Kit 4. Module Removal and Replacement (contd.) 5. Remove the coil retaining screw from the top of the coil. Fig. 4 Removing the Coil Retaining Screw Unplug and remove the coil from the gun manifold by lifting it straight off of the coil connector and module. CAUTION: During coil removal, do not rock the coil from side to side or front to back. This can result in damage to the plastic coil connector Use a hex head wrench and loosen the two module retaining screws by turning them three full turns. 8. Insert a flat screw driver blade between the base of the module and the manifold. Pry the module forward approximately 1.57 mm (.06 in.) to break the seal. 9. Remove the two module retaining screws. 10. Remove the module from the gun manifold Fig. 5 Removing the Gun Module and Coil from the Manifold 1. Coil 2. Coil connector 3. Module retaining screws

5 E-200 Module Service Kit 5 4. Module Removal and Replacement (contd.) 11. Wipe off any adhesive left on the manifold, especially around the adhesive passage. 12. Coat the new o-ring with lubricant. 13. Install the o-ring in the groove in the back of the new module body Fig. 6 Installing the O-ring Apply PTFE paste to the two module retaining screws. 15. Position the module on the gun manifold. Then replace and finger-tighten the two module retaining screws. 16. Install the coil on top of the module, carefully connecting its plug to the coil connector on the manifold. CAUTION: Do not overtighten the screws. Overtightening can cause the head of the screw to break off Fig. 7 Aligning the Module with Gun Manifold 1. Coil 2. Module 3. Module retaining screw 4. Coil retaining screw 17. Tighten the two module retaining screws on the front of the module. Make sure the module is straight and its base is flush with the gun manifold. NOTE: For best results, tighten the screws again after the applicator reaches operating temperature. 18. Reinstall the coil retaining screw on top of the coil. 19. Restore the system to normal operation according to instructions in the applicator service manual.

6 6 E-200 Module Service Kit 5. Alternate Module Removal and Replacement Procedure NOTE: If there is insufficient clearance above the gun s coil for removal from the module at the station or if the gun module and coil are badly charred, use the following alternate method of removing and installing the module and coil as an assembled unit. 1. Relieve hydraulic pressure as described in 3. Unit Preparation in this document. WARNING: Hot! Risk of burns. Hot applicator parts, splashed adhesive, and hot gun surfaces can cause severe burns. Wear long-sleeved, heat-protective clothing, safety goggles, and heat-protective gloves. WARNING: Risk of electrical shock. Failure to observe may result in personal injury or death. 2. Set the applicator circuit breaker to the OFF position. Fig. 8 Turning Off Applicator Circuit Breaker Disconnect and lock out the input power line to the applicator main circuit breaker. 4. Disconnect and lockout power to the driver Fig. 9 Locking Out Input Power

7 E-200 Module Service Kit 7 5. Alternate Module Removal and Replacement Procedure (contd.) 2 5. Use a hex head wrench and loosen the two module retaining screws by turning them three full turns. The coil must still be securely attached to the module by the coil retaining screw. CAUTION: During module/coil removal, do not rock the module from side to side or front to back. This can result in damage to the plastic coil connector Insert a flat screw driver blade between the base of the module and the manifold. Pry the module forward approximately 1.57 mm (.06 in.) to break the seal. 7. Remove the two module retaining screws. Fig. 10 Removing the Module/Coil Assembly 1. Module retaining screws 2. Module/coil Assembly 3. Coil connector 8. Unplug and remove the module/coil as an assembled unit from the manifold by lifting it straight off of the coil connector. 9. Remove the coil retaining screw from the top of the coil. 10. Remove the coil from the top of the module. Be sure to pull the coil straight off of the adapter/pole assembly. 11. Install the coil on top of the replacement module. Be sure the coil is aligned with the back of the module body. 12. Install the coil retaining screw on top of the coil to secure it to the module.

8 8 E-200 Module Service Kit 5. Alternate Module Removal and Replacement Procedure (contd.) 13. Install the o-ring in the grove in the back of the new module body. Fig. 11 Installing the O-ring CAUTION: During module/coil installation, do not rock the module from side to side or front to back. This can result in damage to the plastic coil connector. 14. Install the module/coil assembly onto the manifold by carefully plugging it into the coil connector. Make sure the module/coil assembly is straight and the module base is flush with the gun manifold Apply PTFE paste to the two module retaining screws that secure the module to the manifold. Install and tighten them. 16. Restore the system to normal operation according to instructions in the applicator service manual. 2 Fig. 12 Aligning the Module/Coil Assembly with Gun Manifold 1. Module/coil assembly 2. Module retaining screws Original copyright date Nordson and the Nordson logo registered trademarks of Nordson Corporation.

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