Series H-400 Guns. Customer Product Manual Part D. NORDSON CORPORATION D Duluth, Georgia

Transcription

1 eries H-400 Guns Customer Product Manual Part NORDON CORPORATION D Duluth, Georgia

2 For CE Declaration, refer to melter manual. Nordson Corporation welcomes requests for information, comments and inquiries about its products. General information about Nordson can be found on the Internet using the following address: Address all correspondence to: Nordson Corporation Attn: Customer ervice Lakefield Drive Duluth, GA Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice. Trademarks AquaGuard, Blue Box, Control Coat, Equi=Bead, FoamMelt, FoamMix, Helix, Hot hot, Hot titch, Meltex, Microet, Multican, Nordson, the Nordson logo, Omnican, Package of Values, Porous Coat, Posi-top, ProLink, PRX, RBX, hur-lock, Unican, UpTime, and Versa-pray are registered trademarks of Nordson Corporation. BetterBook, CF, Controlled Fiberization, Eclipse, aturn, eal entry, wirl Coat, and Vista are trademarks of Nordson Corporation.

3 Table of Contents i Table of Contents 1. afety... 1 afety ymbols... 2 Qualified Personnel... 3 Intended Use... 3 Installation and Electrical Connections... 4 Operation... 4 Less-Obvious Dangers... 5 Action in the Event of Unit Malfunction... 5 Danger of Burns... 6 Maintenance/Repair... 6 Cleaning... 7 Thermoplastic Hot Melt Material... 8 Polyurethane Reactive (PUR) Hot Melt Material... 8 Equipment and Material Disposal... 8 Polyurethane Reactive (PUR) Hot Melt Material Description pecifications Dimensions... 11

4 ii Table of Contents 3. Installation Inspection Items Needed Installation Guidelines Mounting the Guns tandard Guns Low-Profile Guns Connecting the Air upply Connecting the Hose Flushing the Guns Preparing for Operation H-400 Gun Operating Range/Adjustment Operating Under 30 bar (450 psi) Hydraulic Pressure Compensating for Low Gun Air Pressure Returning a Gun Module to the Factory etting Operation tarting the ystem Adjusting Adhesive Application hutting Down the ystem Troubleshooting Troubleshooting Table Checking an Air Pressure Regulator Checking for a Clogged Gun Nozzle, Module, or Manifold Checking a Heater Checking an RTD... 29

5 Table of Contents iii 7. Repair Cleaning Nozzles Replacing a Gun Module Replacing a Heater Replacing an RTD Replacing a Gun Manifold Preparation Gun Disassembly Gun Reassembly ystem Restoration Parts Using the Illustrated Parts List Guns, Manifolds, and Heaters Gun Heater pecifications Gun Cordsets and RTDs Gun Module Nozzles olenoid Valves Gun-to-Hose Fittings Accessories... 54

6 iv Table of Contents

7 eries H-400 Guns 1 eries H-400 Guns WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. CAUTION: Risk of equipment damage. H-400 gun modules are adjustable. Adjusting the gun modules for low air pressure operation without making a corresponding reduction in hydraulic pressure may cause the gun modules to remain open. 1. afety afety instructions contained in this section and throughout this document apply to tasks that may be performed with or on the unit. Warnings related to specific safety concerns are included within the text as appropriate. It is very important that these safety instructions are always followed. Failure to do so could result in personal injury and/or damage to the unit or other equipment. With this in mind, here are some basic safety recommendations: Read and become familiar with this afety section prior to installing, operating, maintaining, or repairing the unit. Read and follow the warnings which appear within the text and are related to specific tasks. tore this document within easy reach of personnel operating or maintaining the unit. Wear personal protective equipment and clothing such as safety goggles and gloves. Familiarize yourself with and follow all safety instructions prescribed by your company, general accident-prevention regulations, and government safety regulations. E 200 5Nordson Corporation

8 2 eries H-400 Guns afety ymbols The following symbols are used to warn against dangers or possible sources of danger. Become familiar with them! Failure to heed a warning could lead to personal injury and/or damage to the unit or other equipment. WARNING: Failure to observe may result in personal injury, death, or equipment damage. WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. WARNING: Disconnect equipment from the line voltage. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and/or heat-protective gloves depending on the symbols shown. WARNING: Risk of explosion or fire. Fire, open flames, and smoking prohibited. WARNING: ystem or material pressurized. Relieve pressure. Failure to observe may result in serious burns. CAUTION: Failure to observe may result in equipment damage. CAUTION: Hot surface. Failure to observe may result in burns.

9 eries H-400 Guns 3 Qualified Personnel Qualified personnel is defined here as individuals who thoroughly understand the equipment and its safe operation, maintenance, and repair. Qualified personnel are physically capable of performing the required tasks, familiar with all relevant safety rules and regulations, and have been trained to safely install, operate, maintain, and/or repair the equipment. It is the responsibility of the company operating the equipment to see that its personnel meet these requirements. Intended Use The unit is designed and intended to be used only for the purpose described in the Description section. Uses not in accordance with that section or as described in this document are considered unintended uses and not in accordance with governing regulations. WARNING: Use of this equipment in ways other than described in this document may result in personal injury, death, or equipment damage. The following actions of the owner or operator of the unit are some, but not all, examples of unintended use which would permit Nordson to claim it is not responsible for personal injury or property damage arising from such unintended use: Unapproved modifications or changes to the unit Failure to comply with the safety instructions Failure to comply with instructions concerning installation, use, operation, maintenance, or repair, or when these tasks are carried out by unqualified personnel Use of inappropriate or incompatible foreign materials or auxiliary equipment Failure to observe workplace safety rules or regulations issued by government authorities or safety councils E 200 5Nordson Corporation

10 4 eries H-400 Guns Installation and Electrical Connections WARNING: Failure to follow the safety procedures can result in injury or death. All electrical, pneumatic, gas, and hydraulic connections and installations of hot melt equipment may only be carried out by qualified personnel. Be sure to observe installation instructions for components and accessories. Equipment must be properly grounded and fused according to its rated current consumption (see ID plate). Cables which run outside the unit must regularly be checked for wear or damage. Power supply wire gauge and insulation must be sufficient to handle rated current consumption. Cables must never be squeezed or pinched. Do not locate cables or hoses in high traffic areas. Operation The unit should be operated by qualified personnel in accordance with the instructions presented in this document. WARNING: Failure to follow the safety procedures can result in injury or death. Never allow the unit to be operated by personnel under the influence of substances which reduce their reaction times, or who are not able to operate the equipment for physical reasons. Prior to each start-up of the unit, check protection and warning devices and make sure they are fully functional. Do not operate the unit if these devices are not functioning properly. When the removal of safety equipment is required for installation, maintenance, or repair of the unit, it must be re-connected immediately upon completion of the work. Prior to start-up of the unit, check to make sure all safety guards and safety equipment are in place and functioning properly.

11 eries H-400 Guns 5 In a humid environment, only equipment featuring a corresponding class of protection may be operated. Do not operate the unit in an explosive environment. Keep parts of the body or clothing away from rotating parts. Do not wear loose articles of clothing when operating or servicing units with rotating parts. Take off wrist watches, rings, necklaces, or similar pieces of jewelry and pin up or cover long hair before performing any work on or with the unit. To carry out measurements on work pieces, switch off the unit and wait until it comes to a standstill. Never point hand guns or applicator nozzles at yourself or other persons. Less-Obvious Dangers WARNING: An operator or service technician working with the unit should be aware of less-obvious dangers that often cannot be completely minimized at production sites: Exposed surfaces of the unit which cannot be practically safeguarded. They may be hot and take time to cool after the unit has been operating. The possibility that electrical potentials may remain in the unit after the unit was de-energized Hot melt material and vapors Hydraulically or pneumatically operated parts of the unit Parts winding something up or down which are not covered Action in the Event of Unit Malfunction If the unit malfunctions, switch it off immediately. Turn the circuit breaker or main power switch OFF. Have the unit repaired by qualified personnel only. E 200 5Nordson Corporation

12 6 eries H-400 Guns Danger of Burns Contact with hot melt materials or hot areas of the unit may produce a severe skin burn. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and/or heat-protective gloves depending on the symbols shown. Be extremely careful when using hot melt material. Even solidified material may still be very hot. Always wear protective clothing which safely covers all exposed parts of the body. In case of burns: Immediately cool affected skin areas using cold, clean water. Do not forcefully remove hot melt material from the skin. Immediately seek medical attention. Maintenance/Repair Allow only qualified personnel to perform the procedures described in this document. When performing such tasks, wear protective clothing, and equipment. WARNING: Even when the circuit breaker or main power switch is OFF, the unit is still electrically energized. Complete the following steps prior to maintenance or repair: Disconnect, lock out, and tag external power supply. To ensure the external power supply is disconnected, attempt to operate the unit. If the unit does not energize, proceed with maintenance or repair work. If the unit energizes, repeat the disconnect, lock out, and tag procedure. Re-test the unit.

13 eries H-400 Guns 7 Follow the specific instructions provided in this manual to relieve the system pressure in the entire unit. ecure pneumatically- or hydraulically-operated equipment against uncontrolled movement. Only use parts which do not compromise the safety of the unit. Only use genuine Nordson parts. Always use tools with insulated handles when removing or installing components. Cleaning NOTE: Always refer to the material manufacturer s Material afety Data heet (MD) or material information sheet before working with any material. WARNING: Never clean any aluminum part or flush any system using halogenated hydrocarbon fluids. Examples of common halogenated hydrocarbons are: dichloromethylene, 1,1,1-trichloroethylene, and perchloroethylene. Halogenated hydrocarbons may react violently with aluminum parts. WARNING: Fire, open flame, and smoking are prohibited when cleaning fluids are used. Observe all explosion prevention regulations. Cleaning fluids may only be heated using temperature-controlled and explosion-protected heaters. Never use an open flame to clean the unit or components of the unit. Use only cleaning fluids designed or intended to be used with the hot melt material being used in the unit. Never use paint fluids under any circumstances. Note the flash point of the cleaning fluid used. Only use a controlled heating method to heat fluids. Ensure sufficient room ventilation to draw off generated vapors. Avoid prolonged breathing of vapors. E 200 5Nordson Corporation

14 8 eries H-400 Guns Thermoplastic Hot Melt Material NOTE: Always refer to the material manufacturer s Material afety Data heet (MD) or material information sheet before working with any hot melt material. Polyurethane Reactive (PUR) Hot Melt Material Ensure the work area is adequately ventilated. Do not exceed recommended processing temperatures. Doing so creates a danger to personnel due to decomposition of the material. Equipment and Material Disposal Dispose of equipment and materials used in operation and cleaning according to local regulations. Polyurethane Reactive (PUR) Hot Melt Material NOTE: Always refer to the material manufacturer s Material afety Data heet (MD) or material information sheet before working with any hot melt material. WARNING: Exercise extreme caution and always provide adequate ventilation when using reactive materials. WARNING: Only use PUR material in units that are designed to process such material. Using PUR material in units that cannot process them can cause damage to the unit and premature reaction of the hot melt material. WARNING: PUR material contains isocyanate ingredients which will irritate skin, mucous membranes of eyes and respiratory passages. WARNING: Persons with existing asthmatic conditions may experience difficulty in breathing.

15 eries H-400 Guns 9 Because isocyanate ingredients are found in various concentrations in reactive materials produced by different manufacturers, it is imperative that the material manufacturer s MD or material information sheet be consulted before using reactive material. Pay particular attention to the discussion of material toxicity, health effects, and reactivity condition. There are certain universal safety guidelines that should be followed when using any reactive material: Recommended processing temperatures must not be exceeded. When handling and using reactive material, always wear thermally protective gloves and long-sleeved clothing. Wear chemical goggles to reduce the potential of eye contact. Have eye washes available and provide a cold water source for burn treatment. The regular use of barrier cream for hands and face is recommended for skin protection. Do not eat, drink, smoke, or store food in working areas where PUR material is being processed. Wash hands thoroughly after working with reactive material. Remove hot melt material vapors using suitable extraction ventilation equipment. Use appropriate respiratory equipment where there is the danger of inhaling isocyanate vapors or other ingredients contained in the PUR material in concentrations exceeding permissible limit values. In case of very high concentrations of harmful substances, or if you are unsure of the environmental conditions, respiratory protective equipment (operating independent of the surrounding air) must be used. Do not operate the unit with PUR materials if you are unsure that all adequate safety measures have been taken. E 200 5Nordson Corporation

16 10 eries H-400 Guns 2. Description Nordson eries H-400 guns are used to apply thermoplastic hot melt adhesive to a product. Polyurethane-reactive (PUR) and high-temperature polyamide adhesives can negatively affect gun performance and durability. The H-400 gun product line includes a choice of valve seat, single- and multi-module configurations, and a wide selection of nozzles. H-400 guns provide continuous operation and consistent adhesive output, minimizing delays. H-400 guns use resistance temperature detectors (RTDs) for precise temperature sensing and control of gun temperature to within ±0.5 C (1.0 F) of a setpoint temperature. Figure 1 shows a typical eries H-400 gun A Fig. 1 H-400 Gun Components 1. olenoid valve 2. Pipe nipple 3. Mounting clamp 4. Mounting bar 5. Insulator 6. Cordset 7. Gun manifold 8. Gun-to-hose fitting 9. Gun module

17 eries H-400 Guns 11 pecifications Operating temperature Item pecification Note Operating hydraulic pressure 232 _C (450 _F) maximum 90 bar (1,300 psi) maximum Operating air pressure bar ( psi) A Operating speed exceeds 4,500 cycles per minute Nozzles eries 237 XXX, 238 XXX, right-angle, and aturn nozzles B Electrical service Approvals and certifications 240 Vac, 50/60 Hz 200 Vac, 50/60 Hz (for low-voltage areas) Underwriter s Laboratories (UL), TÜV Rheinland of North America, Communité Européen (CE) NOTE A: Use dry, regulated, unlubricated air for consistent gun operation. B: eries H-400 gun modules use the same nozzles as eries H-200 gun modules. Dimensions 40.4 mm (1.59 in.) 22.2 mm (0.875 in.) mm (4.52 in.) 96.5 mm (3.80 in.) 83 mm (3.25 in.) 83.8 mm (3.30 in.) 12.7 mm 42.2 mm (0.50 in.) (1.66 in.) 40.4 mm 25.4 mm (1.59 in.) (1.0 in.) A Fig. 2 H-400 Gun Dimensions E 200 5Nordson Corporation

18 12 eries H-400 Guns 3. Installation eries H-400 guns are designed for use with Nordson hot melt units and hoses. This section provides guidelines and procedures for installing H-400 guns. Inspection Exercise normal care to prevent equipment damage during unpacking. After unpacking the equipment, inspect it for any damage that may have occurred during shipping. Look for dents and scratches and make sure all fasteners are tight. Report any damage to your Nordson representative. Items Needed The following items are needed to install H-400 guns. Hot melt unit and associated equipment manuals Automatic gun hoses Mounting equipment olenoid valves (one or more per gun) Air pressure regulator and air line tubing Drain pan Wrenches and screwdrivers afety goggles, safety gloves, and long-sleeved heat-protective clothing Installation Guidelines Use the following installation guidelines to obtain optimum gun performance. Mount the guns so the nozzles are no more than 13 mm (0.5 in.) from the product. Protect the guns from vibration and secure them so they will not change position during application. Insulate hose-to-gun joints.

19 eries H-400 Guns 13 Do not use extra fittings to connect the hose to the gun. Nordson offers straight, 45_, and 90_ filtered and nonfiltered gun-to-hose fittings. Refer to Parts. Make sure the gun air pressure regulator is capable of providing a minimum of 3.4 bar (50 psi) to the solenoid valve. Use a solenoid valve that is rated above 0.5 Cv. Refer to Parts. NOTE: olenoid valves rated below 0.5 Cv restrict gun performance and result in significantly higher air section failures in Nordson product conformance tests. Use Nordson precision nozzles. Refer to Parts. Mounting theguns H-400 guns are equipped with a mounting clamp. Variations in mounting may be required depending on your equipment and production line. Regardless of the mounting method used, refer to the Installation Guidelines to obtain optimum gun performance. Use the appropriate procedure, tandard Guns or Low-Profile Guns, for the type of guns you are installing. E 200 5Nordson Corporation

20 14 eries H-400 Guns tandard Guns 1. ee Figure 3. Loosen the mounting clamp hex screw (1) and pan-head screws (2). 2. lide a mounting bar (3) through the clamp. NOTE: If you are adding a new gun to an existing system, or replacing a gun, remove the hex screw and the pan-head screws from the mounting clamp, position the upper and lower pieces of the mounting clamp on the mounting bar, then loosely screw the hex screw and pan-head screws through both pieces of the mounting clamp A Fig. 3 H-400 Gun Installation 1. Loosening the hex screw 2. Loosening the pan-head screws 3. Installing the mounting bar 3. Finger-tighten the hex and pan-head screws. 4. ecure the mounting bar on your equipment so there will be no gun movement. 5. Loosen the hex and pan-head screws and slide the gun to the desired position on the mounting bar. 6. ecurely tighten the hex and pan-head screws.

21 eries H-400 Guns 15 Low-Profile Guns ee Figure 4. ecure the mounting rod to the parent machine. Position the gun as close to the adhesive application point as the product clearance will allow A Fig. 4 Typical Low-Profile Gun (shown with solenoid valve installed) Connecting the Air upply Use this procedure to install a gun solenoid valve and to connect the air supply to the valve. Use dry, regulated, unlubricated air for consistent gun operation. CAUTION: Risk of solenoid valve failure. A solenoid valve can be damaged if its voltage rating does not match the output voltage from the power supply or if it does not meet high-temperature standards. Refer to Parts for solenoid valve voltage ratings and a list of valves suitable for use at service temperatures above 85 _C (185 _F). 1. ee Figure 5. Connect one end of the pipe nipple to a solenoid valve (1). 2. Apply anti-seize lubricant to the threads of a 1 / 8 -in. pipe nipple. E 200 5Nordson Corporation

22 16 eries H-400 Guns Connecting the Air upply (contd.) 3. Connect the other end of the pipe nipple to the gun manifold air input port (2). NOTE: Figure 4 shows a solenoid valve installed on a low-profile gun A Fig. 5 Installing a olenoid Valve 1. Connecting pipe nipple to the valve 2. Connecting the valve to the gun 4. Connect an air supply line to the solenoid valve. 5. Install an air pressure regulator and gauge in the air supply line. 6. Make sure the air supply line has a shutoff valve. 7. Connect the solenoid valve to a power supply. The power supply can be a timer or a pattern controller. Refer to the solenoid valve manufacturer s instructions. Connecting thehose Follow this procedure to connect a hose to the gun. CAUTION: Risk of equipment damage. Do not use nonconductive pipe compound or tape on gun and hose hydraulic connections. 1. Thread the hose swivel fitting onto the gun hose fitting until the connection is finger tight.

23 eries H-400 Guns ee Figure 6. Use two wrenches to tighten the hose-to-gun fitting (1). Place one wrench on the hose fitting and the other on the gun fitting. 3. Plug the gun cordset into the hose plug receptacle (2). 1 2 Fig. 6 Connecting the Hose to the Gun 1. Tightening the hose-to-gun fitting 2. Plugging in the cordset A 4. Connect the hose to your hot melt unit by following the instructions in the unit manual. Flushing theguns Prior to installing nozzles, flush the guns to purge them of air and shipping or installation contamination. 1. Turn on the hot melt unit and allow it to reach operating temperature. Refer to your unit manual for the startup procedure. 2. Place a drain pan under all guns. 3. Turn on the pump. Refer to your unit manual for the pump startup procedure. 4. Follow the system startup procedure in your unit manual. Trigger the guns on by manually activating the solenoid valve and flush the guns until the adhesive flowing from them is clear. WARNING: ystem or material pressurized. Relieve pressure. Failure to observe this warning may result in serious injury. 5. Turn off the pump and relieve hydraulic pressure. Refer to your unit manual. E 200 5Nordson Corporation

24 18 eries H-400 Guns Preparing for Operation Follow this procedure to complete the installation process and to set up your unit for normal operation. 1. Install nozzles on the guns: Install one-piece nozzles by screwing the nozzle onto the gun module with a gloved hand. Tighten the nozzle no more than 4.5 Nm (40 in.-lb). Install retaining nut nozzles by placing the nozzle inside the retaining nut, then screwing the retaining nut onto to the gun module with a gloved hand. Tighten to no more than 4.5 Nm (40 in.-lb). 2. Turn on the pump. 3. Adjust the gun air pressure and the hydraulic pressure to the desired settings. The operating gun air pressure range is bar ( psi). The operating hydraulic pressure range is bar (450--1,300 psi). NOTE: These pressure ranges are appropriate for most packaging and product assembly applications. However, if your application requires operating at a hydraulic pressure below 30 bar (450 psi), you may need to adjust the gun air pressure or the gun module. Refer to the next section, H-400 Gun Operating Range/Adjustment.

25 eries H-400 Guns H-400 Gun Operating Range/Adjustment Use these procedures to make adjustments that will allow you to operate an H-400 gun at a hydraulic pressure under 30 bar (450 psi). Operating Under 30 bar (450 psi) Hydraulic Pressure To operate at a hydraulic pressure under 30 bar (450 psi), increase the gun air pressure. Refer to Table 1. This will allow you to operate at a hydraulic pressure as low as 14 bar (200 psi). If you cannot achieve gun air pressure above 3.4 bar (50 psi), go to the next procedure, Compensating for Low Gun Air Pressure. If the gun air pressure is... Table 1 Increasing Gun Air Pressure to Operate at Low Hydraulic Pressure The minimum hydraulic pressure is bar (50 psi) 30 bar (450 psi) And the maximum hydraulic pressure is bar (60 psi) 20 bar (300 psi) 90 bar (1,300 psi) greater than 4.8 bar (70 psi) 14 bar (200 psi) E 200 5Nordson Corporation

26 20 eries H-400 Guns Compensating for Low Gun Air Pressure If you have insufficient gun air pressure but are required to operate at a hydraulic pressure under 30 bar (450 psi), you must reduce the gun module spring tension. Because this adjustment is independent of the factory-set stroke, the gun module operating speed and life will not be affected. WARNING: Risk of burns. Reducing the gun module spring tension also reduces the maximum hydraulic pressure at which the module will self-relieve or free-flow. If the maximum hydraulic pressure is exceeded, the gun module will remain open and dispense adhesive uncontrollably. ee Figure 7. To reduce the spring tension, loosen the locking nut (2) and turn the adjusting screw (1) counterclockwise in 1 / 2 -turn increments. Each 1 / 2 turn reduces the hydraulic pressure capability by 7 bar (100 psi). RefertoTable2. Table 2 Adjusting the Gun Module to Operate at Low Gun Air Pressure and Low Hydraulic Pressure Adjusting crew Position Minimum Gun Air Pressure Minimum Hydraulic Pressure Maximum Hydraulic Pressure Factory setting 30 bar (450 psi) 90 bar (1,300 psi) Approximately 1 / 2 turn counterclockwise from factory setting Approximately 1 turn counterclockwise from factory setting 3.4 bar (50 psi) 33 bar (350 psi) 83 bar (1,200 psi) 26 bar (250 psi) 76 bar (1,100 psi) A Fig. 7 Gun Module Locking Nut and Adjusting crew 1. Adjusting screw 2. Locking nut

27 eries H-400 Guns 21 Returning a Gun Module tothe Factory etting Follow this procedure to return a gun module to the original factory setting. 1. Loosen the locking nut. 2. Turn the adjusting screw clockwise only until it bottoms out. Do not over-tighten the screw. 3. Turn the adjusting screw counterclockwise two revolutions. The air cap is marked to allow you to precisely reset the screw. 4. Tighten the locking nut while holding the adjusting screw in place. 5. Operation This section contains operating procedures for installed H-400 guns. Make sure you have completed Flushing the Guns and Preparing for Operation in Installation before using these procedures. tarting theystem Follow this procedure to start your hot melt system. CAUTION: Risk of equipment damage. Nordson Corporation recommends turning off the gun air supply during system startup to prevent unexpected pressure buildup in the module and gun manifold caused by the expansion of the cold adhesive as it melts. 1. Make sure the gun air supply is turned off. 2. Turn on the hot melt unit and allow it to reach operating temperature. Refer to your unit manual for the startup procedure. 3. Turn on the gun air supply. 4. Turn on the solenoid valve power supply, enable any triggering devices, and start the production line. E 200 5Nordson Corporation

28 22 eries H-400 Guns Adjusting Adhesive Application To modify how adhesive is applied: Adjust the adhesive temperature. Refer to the adhesive manufacturer s data sheet. Adjust the nozzle distance from the product. The distance should be 13 mm (0.5 in.) or less. Change your nozzle selection. NOTE: elect a nozzle with an engagement length and hole size that will allow the gun to operate above 17 bar (250 psi). Operating below this pressure can result in stringing and cutoff problems in most adhesives. Adjust the gun air pressure. The operating range is bar ( psi). Adjust the hydraulic pressure. The operating range is bar (450--1,300 psi). NOTE: These pressure ranges are appropriate for most packaging and product assembly applications. However, if your application requires operating at a hydraulic pressure below 30 bar (450 psi), you may need to adjust the gun air pressure or the gun module. Refer to H-400 Gun Operating Range/Adjustment.

29 eries H-400 Guns 23 hutting Down the ystem Follow this procedure to shut down your hot melt system. 1. top the production line. WARNING: ystem or material pressurized. Relieve pressure. Failure to observe this warning may result in serious injury. 2. Turn off the pump and relieve hydraulic pressure. Refer to your unit manual. 3. Turn off the unit. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and heat-protective gloves. 4. Place a drain pan under all guns. 5. Manually trigger the guns until they are drained of adhesive. 6. Turn off the solenoid valve power supply. 7. Turn off the gun air supply. 8. Manually trigger the gun solenoid valves to relieve gun air pressure. E 200 5Nordson Corporation

30 24 eries H-400 Guns 6. Troubleshooting The following troubleshooting table describes the kinds of problems you may encounter and provides corrective actions for handling those problems. When necessary, the table refers to more detailed diagnostic procedures. Refer to your hot melt unit manual for further troubleshooting procedures. Troubleshooting Table Problem Possible Cause Corrective Action 1. No adhesive output from gun modules 2. Inconsistent output or continuous output 3. Gun under-heats or overheats ystem not at operating temperature Adhesive level too low Low or no hydraulic pressure No input power Low or no input air pressure to solenoid valve olenoid valve malfunctioning or power supply to solenoid valve insufficient Clogged gun nozzle, module, or manifold Gun not adjusted for low operating pressure (under 30 bar [450 psi]) Failed heater Failed RTD Wait for the system to reach operating temperature or adjust the operating temperature setpoints. Refer to your unit manual. Add adhesive. Refer to your unit manual. Check the hydraulic pressure. Refer to the hydraulic system troubleshooting procedures in your unit manual. Make sure the gun cordset connection is tight and the solenoid valve power supply is turned on. Check the air pressure regulator. Refer to Checking an Air Pressure Regulator. Check the solenoid valve and the power supply to the valve. Refer to the manufacturer s instructions. Refer to Checking for a Clogged Gun Nozzle, Module, or Manifold. Refer to the H-400 Gun Operating Range/Adjustment section. Refer to Checking a Heater. Refer to Checking an RTD.

31 eries H-400 Guns 25 Checking an Air Pressure Regulator Use this procedure as directed by the Troubleshooting Table to check the gun air pressure regulator. 1. et the air pressure regulator to Turn off the air to the regulator at the air supply source. 3. Disconnect the solenoid valve air line from the regulator. 4. Restore air pressure to the regulator. 5. Gradually turn on the regulator to verify that air is flowing through it. No air flows from the regulator: regulator defective. Replace the regulator. Air flows from the regulator: normal indication. Return the air pressure to 0 and reconnect the air line to the regulator. Return to the Troubleshooting Table. Checking for a Clogged Gun Nozzle, Module, or Manifold Use this procedure as directed by the Troubleshooting Table to check for a clogged gun nozzle, module, or manifold. WARNING: ystem or material pressurized. Relieve pressure. Failure to observe this warning can result in serious injury. 1. Turn off the pump and relieve hydraulic pressure. Refer to your unit manual. 2. Turn off the gun air supply. 3. Place a drain pan under the gun. 4. Manually trigger the gun until it is drained of adhesive. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and heat-protective gloves. 5. Use a wrench to loosen the nozzle, then remove the nozzle by hand. E 200 5Nordson Corporation

32 26 eries H-400 Guns Checking for a Clogged Gun Nozzle, Module, or Manifold (contd.) 6. Restore air pressure to the gun solenoid valve. 7. Turn on the pump. 8. Trigger the gun by manually activating the solenoid valve. Adhesive flows from the gun module: nozzle clogged. Clean the nozzle. Refer to Cleaning Nozzles in Repair. No adhesive flows from the gun module: gun module may be clogged. Return the air pressure to 0 and continue to the next step. WARNING: ystem or material pressurized. Relieve pressure. Failure to observe this warning can result in serious injury. 9. Turn off the pump and relieve hydraulic pressure. Refer to your unit manual. 10. Remove the two socket-head screws that secure the gun module to the gun manifold and remove the module. 11. Restore air pressure to the gun solenoid valve. 12. Turn on the pump. 13. Trigger the gun by manually activating the solenoid valve. Adhesive flows from the gun manifold: module clogged. Replace the module. Refer to Replacing a Gun Module in Repair. No adhesive flows from the gun manifold: the gun manifold is clogged or there is blockage in the hose or unit. To replace the gun manifold, refer to Replacing a Gun Manifold. Refer to your unit manual for further hydraulic system troubleshooting procedures.

33 eries H-400 Guns 27 Checking a Heater Use this procedure as directed by the Troubleshooting Table to check the gun heater. WARNING: ystem or material pressurized. Relieve pressure. Failure to observe this warning may result in serious injury. 1. Turn off the pump and relieve hydraulic pressure. Refer to your unit manual. WARNING: Disconnect equipment from the line voltage. Failure to observe this warning can result in personal injury or death. 2. Turn off the unit; then disconnect and lock out electrical power to the unit. 3. Place a drain pan under the gun. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and heat-protective gloves. 4. Manually trigger the gun until it is drained of adhesive. 5. Turn off the gun air supply. 6. Unplug the gun cordset. E 200 5Nordson Corporation

34 28 eries H-400 Guns Checking a Heater (contd.) 7. ee Figure 8. Use a standard ohmmeter to check the heater circuit at the cordset pins. Circuit not open: normal indication. Return to the Troubleshooting Table. Circuit open: loose connection between heater and cordset or failed heater. Tighten the loose connection or replace the heater as appropriate. Refer to Replacing a Heater in Repair. RTD HEATER 1 HEATER RTD RTD GND Fig. 8 Typical Gun Cordset

35 eries H-400 Guns 29 Checking an RTD Use this procedure as directed by the Troubleshooting Table to check the gun RTD. WARNING: ystem or material pressurized. Relieve pressure. Failure to observe this warning may result in serious injury. 1. Turn off the pump and relieve hydraulic pressure. Refer to your unit manual. WARNING: Disconnect equipment from the line voltage. Failure to observe this warning can result in personal injury or death. 2. Turn off the unit; then disconnect and lock out electrical power to the unit. 3. Place a drain pan under the gun. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and heat-protective gloves. 4. Manually trigger the gun until it is drained of adhesive. 5. Turn off the gun air supply. 6. Wait until the gun reaches room temperature. 7. Unplug the gun cordset. 8. ee Figure 8. Use an ohmmeter to test the RTD resistance at the cordset pins. ee Figure 9. Resistance reading within appropriate range shown on chart: normal indication. Return to the Troubleshooting Table. Resistance reading not within appropriate range shown on chart: Failed RTD. Replace the RTD. Refer to Replacing an RTD in Repair. NOTE: This is a reference check only. The indicated gun temperature, the gun surface temperature, and the RTD actual temperature can vary by up to 10%. E 200 5Nordson Corporation

36 30 eries H-400 Guns Checking an RTD (contd.) REITANCE IN OHM TEMPERATURE REITANCE IN OHM TEMPERATURE Fig. 9 RTD Resistance vs. RTD Temperature

37 eries H-400 Guns Repair Troubleshooting contains diagnostic procedures which may identify failed components. This section contains procedures for cleaning nozzles and for replacing a gun module, heater, RTD, or manifold. Refer to Parts to order replacement parts. Cleaning Nozzles Follow this procedure to clean clogged nozzles. WARNING: ystem or material pressurized. Relieve pressure. Failure to observe this warning may result in serious injury. 1. Turn off the pump and relieve hydraulic pressure. Refer to your unit manual. 2. Turn off the unit. 3. Place a drain pan under all guns. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and heat-protective gloves. 4. Manually trigger the guns until they are drained of adhesive. 5. Turn off the gun air supply. 6. Turn off the solenoid valve power supply. 7. ee Figure 10. Use a wrench to loosen the nozzles (1); then remove the nozzles by hand (2). 1 2 Fig. 10 Removing a Nozzle 1. Loosening the nozzle 2. Removing the nozzle A E 200 5Nordson Corporation

38 32 eries H-400 Guns Cleaning Nozzles (contd.) WARNING: Risk of personal injury or death. If heated above 245 _C (475 _F), Type-R fluid can cause an explosion or fire. Do not heat Type-R fluid with an open flame or in an unregulated heating device. Use a controlled heating device, such as a small deep-fat fryer or a thermostatically controlled hot plate. 8. Place the nozzles in a container of Type-R cleaning fluid. 9. Heat the cleaning fluid above the adhesive s melting temperature. 10. ee Figure 11. Remove the nozzles from the cleaning fluid and clean them using a pin-type probe. NOTE: Nordson Corporation offers a nozzle cleaning kit. Refer to Parts. Fig. 11 Cleaning Nozzles A 11. Reinstall the nozzles on the guns and restore the system to normal operation.

39 eries H-400 Guns 33 Replacing a Gun Module Use this procedure to replace a gun module. WARNING: ystem or material pressurized. Relieve pressure. Failure to observe this warning may result in serious injury. 1. Turn off the pump and relieve hydraulic pressure. Refer to your unit manual. WARNING: Disconnect equipment from the line voltage. Failure to observe this warning can result in personal injury or death. 2. Turn off the unit; then disconnect and lock out electrical power to the unit. 3. Place a drain pan under the gun. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and heat-protective gloves. 4. Manually trigger the gun until it is drained of adhesive. 5. Turn off the gun air supply. 6. Use a wrench to loosen the nozzle; then remove the nozzle by hand. E 200 5Nordson Corporation

40 34 eries H-400 Guns Replacing a Gun Module (contd.) 7. ee Figure 12. Remove the two socket-head screws that secure the module to the gun manifold and remove the module A Fig. 12 Replacing a Module 8. Wipe off any adhesive on the gun manifold and check for adhesive in the air supply ports. 9. Make sure the O-rings on the back of the gun module are properly positioned. 10. Apply anti-seize lubricant to the gun module socket-head screws and secure the new module to the gun manifold with the screws. Tighten to 3.3 Nm (30 in.-lb). 11. Reinstall the nozzle on the new gun module and restore the system to normal operation. NOTE: The H-400 gun module is factory-set to operate properly between bar ( psi) gun air pressure and bar (450--1,300 psi) hydraulic pressure. This setting is appropriate for most packaging and product assembly applications. However, if your application requires operating at a hydraulic pressure below 30 bar (450 psi), refer to H-400 Gun Operating Range/Adjustment.

41 eries H-400 Guns 35 Replacing a Heater Follow this procedure to replace a gun heater. A gun may have one or two heaters. WARNING: ystem or material pressurized. Relieve pressure. Failure to observe this warning may result in serious injury. 1. Turn off the pump and relieve hydraulic pressure. Refer to your unit manual. WARNING: Disconnect equipment from the line voltage. Failure to observe this warning can result in personal injury or death. 2. Turn off the unit; then disconnect and lock out electrical power to the unit. 3. Place a drain pan under the gun. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and heat-protective gloves. 4. Manually trigger the gun until it is drained of adhesive. 5. Turn off the gun air supply. 6. Unplug the gun cordset. 7. Use two wrenches to disconnect the hose from the gun. Place one wrench on the gun fitting and one on the hose fitting. 8. Remove the gun manifold cover screws and move the cover away from the gun. 9. Remove the terminal block and loosen the screws that secure the heater wires. E 200 5Nordson Corporation

42 36 eries H-400 Guns Replacing a Heater (contd.) 10. Remove and discard the defective heater. NOTE: If the heater is stuck, use a punch or similar tool to tap the heater loose from the opposite end. 11. Trim the heater wires to match the old heater wire length. 12. trip about 6 mm ( 1 / 4 in.) of insulation from each wire. 13. ee Figure 13. Insert an eyelet into each heater wire terminal block opening; then insert the heater wires into the eyelets. If the gun has two heaters, two heater wires may be placed in the same eyelet Fig. 13 Gun Electrical Connections 1. Heater 2. Terminal block 3. Cordset 4. Ground wire 5. RTD 14. Crimp the eyelets by tightening the terminal block screws. Tighten to approximately 0.49 Nm (70 in.-oz). 15. Insert the new heater in the gun manifold.

43 eries H-400 Guns Position the terminal block in the gun manifold, arranging the wiring so it will not be pinched when the gun manifold cover is closed. 17. Reposition and secure the gun manifold cover. 18. Use two wrenches to reconnect the gun to the hose. Place one wrench on the gun fitting and one on the hose fitting. 19. Plug the gun s cordset into the hose plug receptacle. 20. Restore electrical power to the unit and resume normal operation. Replacing an RTD Follow this procedure to replace an RTD. To replace the RTD you will need to install a new cordset. WARNING: ystem or material pressurized. Relieve pressure. Failure to observe this warning may result in serious injury. 1. Turn off the pump and relieve hydraulic pressure. Refer to your unit manual. WARNING: Disconnect equipment from the line voltage. Failure to observe this warning can result in personal injury or death. 2. Turn off the unit; then disconnect and lock out electrical power to the unit. 3. Place a drain pan under the gun. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and heat-protective gloves. 4. Manually trigger the gun until it is drained of adhesive. 5. Turn off the gun air supply. 6. Unplug the gun cordset. E 200 5Nordson Corporation

44 38 eries H-400 Guns Replacing an RTD (contd.) 7. Use two wrenches to disconnect the hose from the gun. Place one wrench on the gun fitting and one on the hose fitting. 8. ee Figure 14. Remove the gun manifold cover screws (3) and move the cover (2) away from the gun. 9. Remove the cordset wires (5) from the terminal block or blocks. NOTE: Don t remove the heater wires from the terminal block or blocks. 10. Disconnect the ground wire (1). 11. Unscrew the cordset locking nut and pull the cordset (4), including the RTD (6), loose from the gun manifold cover A Fig. 14 Replacing an RTD (typical gun shown) 1. Ground wire 2. Gun manifold cover 3. crews 4. Cordset 5. Cordset wires 6. RTD

45 eries H-400 Guns Insert the new cordset wires through the gun manifold cover, the washer, and the locking nut and tighten the locking nut. 13. Insert the cordset wires in the terminal block or blocks and tighten the terminal block screws to approximately 0.49 Nm (70 in.-oz). 14. Connect the ground wire. 15. Insert the RTD in the gun manifold. 16. Position the terminal block in the gun manifold, arranging the wiring so it will not be pinched when the gun manifold cover is secured. 17. Reposition and secure the gun manifold cover. 18. Use two wrenches to reconnect the gun to the hose. Place one wrench on the gun fitting and one on the hose fitting. 19. Plug the gun s cordset into the hose plug receptacle. 20. Restore electrical power to the unit and resume normal operation. Replacing a Gun Manifold Follow these procedures to replace a gun manifold. Preparation WARNING: ystem or material pressurized. Relieve pressure. Failure to observe this warning may result in serious injury. 1. Turn off the pump and relieve hydraulic pressure. Refer to your unit manual. WARNING: Disconnect equipment from the line voltage. Failure to observe this warning can result in personal injury or death. 2. Turn off the unit; then disconnect and lock out electrical power to the unit. E 200 5Nordson Corporation

46 40 eries H-400 Guns Replacing a Gun Manifold (contd.) 3. Place a drain pan under the gun. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and heat-protective gloves. 4. Manually trigger the gun until it is drained of adhesive. 5. Turn off the gun air supply. 6. Unplug the gun cordset. 7. Use two wrenches to disconnect the hose from the gun. Place one wrench on the gun fitting and one on the hose fitting. 8. Disconnect the solenoid valve from the air supply and power supply; then disconnect the pipe nipple from the gun manifold. 9. Remove the mounting clamp hex screw; then loosen the pan-head screws until the gun, with the mounting clamp attached, can be removed from the mounting bar. Gun Disassembly 1. ee Figure 15. Remove the mounting clamp (3) and insulator from the gun manifold. 2. Remove the two socket-head screws (1) that secure the gun module (2) to the gun manifold (8) and remove the module. 3. Remove the gun manifold cover screws (5) and move the cover (4) away from the gun. 4. Disconnect the ground wire (9). 5. Remove the RTD (10) and the heater or heaters (11). NOTE: On most guns a punch can be used to loosen a stuck RTD or heater. Insert the punch at the end opposite the wires.

47 eries H-400 Guns If applicable, unscrew the cordset (6) from the gun manifold. The gun manifold cover and cordset should now be completely disconnected from the gun manifold. 7. Remove the gun-to-hose fitting and O-ring (7) A Fig. 15 H-400 Gun Disassembly (typical gun shown) 1. ocket-head screw 2. Gun module 3. Mounting clamp and insulator 4. Gun manifold cover 5. crews 6. Cordset 7. Gun-to-hose fitting and O-ring 8. Gun manifold 9. Ground wire 10. RTD 11. Heater Gun Reassembly 1. Connect the ground wire to the new gun manifold. 2. Insert the RTD in the gun manifold. 3. Insert the heater or heaters in the gun manifold. E 200 5Nordson Corporation

48 42 eries H-400 Guns Gun Reassembly (contd.) 4. Apply anti-seize lubricant to the gun-to-hose fitting threads and reinstall the fitting and the O-ring. CAUTION: Risk of equipment damage. When reinstalling the gun manifold cover, do not pinch the wires between the cover and the gun manifold. 5. Position the gun manifold cover and secure it with the cover screws. CAUTION: Do not overtighten the gun module socket-head screws. Overtightening can strip the threads. 6. Apply anti-seize lubricant to the gun module socket-head screws and secure the new module to the gun manifold with the screws. Tighten to 3.3 Nm (30 in.-lb). 7. Loosely connect the mounting clamp and insulator to the gun manifold. ystem Restoration 1. Reinstall and secure the gun on the mounting bar. 2. Apply anti-seize lubricant to the pipe nipple threads and reconnect the pipe nipple to the gun manifold; then reconnect the solenoid valve to the air supply and triggering device. 3. Plug the gun s cordset into the hose plug receptacle. 4. Use two wrenches to secure the hose to the gun. Place one wrench on the gun fitting and one on the hose fitting. 5. Remove the lock-out and restore electrical power to the unit; then turn the unit on. 6. Allow the unit to reach operating temperature and turn on the pump. 7. Check for leaks at the hose-to-gun fitting. Tighten any loose fittings. 8. Flush the gun. Refer to Flushing the Guns in Installation.

49 eries H-400 Guns Parts To order parts, contact the Nordson Customer ervice Center or your local Nordson representative. Use the following parts lists to describe and locate parts correctly. Using the Illustrated Parts List Numbers in the Item column correspond to numbers that identify parts in illustrations following each parts list. The code N (not shown) indicates that a listed part is not illustrated. A dash ( ) is used when the part number applies to all parts in the illustration. The six-digit number in the Part column is the Nordson Corporation part number. Aseriesofdashesinthiscolumn(------)means the part cannot be ordered separately. The Description column gives the part name, as well as its dimensions and other characteristics when appropriate. Indentions show the relationships between assemblies, subassemblies, and parts. Item Part Description Quantity Note Assembly ubassembly 2 A Part 1 If you order the assembly, items 1 and 2 will be included. If you order item 1, item 2 will be included. If you order item 2, you will receive item 2 only. The number in the Quantity column is the quantity required per unit, assembly, or subassembly. The code AR (As Required) is used if the part number is a bulk item ordered in quantities or if the quantity per assembly depends on the product version or model. Letters in the Note column refer to notes at the end of each parts list. Notes contain important information about usage and ordering. pecial attention should be given to notes. E 200 5Nordson Corporation