MiniBlue Guns. Customer Product Manual Part A02. Issued 1/08. NORDSON CORPORATION DULUTH, GEORGIA USA

Transcription

1 MiniBlue Guns Customer Product Manual Issued 1/08 NORDSON CORPORATION DULUTH, GEORGIA USA

2 For CE Declaration, refer to melter documentation. 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 Service 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 AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve, CleanSpray, ColorMax, Color-on-Demand, Control Coat, Coolwave, Cross-Cut, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber, DuraPail, Dura-Screen, Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo-Coat, e.dot, EFD, ESP, e stylized, ETI, Excel 2000, Fillmaster, FlexiCoat, Flex-O-Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, HDLV, Heli-flow, Helix, Horizon, Hot Shot, icontrol, iflow, isocoil, Isocore, Iso-Flo, itrax, Kinetix, Lean Cell, Little Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark, MicroSet, Millennium, Mini Squirt, Mountaingate, MultiScan, Nordson, OptiMix, Package of Values, Pattern View, PermaFlo, Plasmod, Porous Coat, PowderGrid, Powderware, PRIMARC, Printplus, Prism, ProBlue, Prodigy, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Scoreguard, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, SureBead, Sure Clean, Sure Coat, Sure-Max, Tracking Plus, TRAK, Trends, Tribomatic, TrueBlue, Ultra, Ultrasaver, UpTime, u TAH, Vantage, Veritec, VersaBlue, Versa-Coat, Versa-Screen, Versa-Spray, Walcom, Watermark, and When you expect more. are registered trademarks of Nordson Corporation. Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AquaCure, ATS, Auto-Flo, AutoScan, Best Choice, Blue Series, Bowtie, Bravura, Check Mate, ClassicBlue, Classic IX, Controlled Fiberization, Control Weave, CountourCoat, CPX, CScan, Cyclo-Kinetic, DispensLink, DropCure, Dry Cure, DuraBraid, DuraCoat, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+, Emerald, Encore, E-Nordson, Equi=Bead, FillEasy, Fill Sentry, Fluxplus, Get Green With Blue, GreenUV, G-Net, G-Site, idry, ion, Iso-Flex, itrend, Lacquer Cure, Maxima, MicroFin, MicroMax, Mikros, MiniBlue, MiniEdge, Minimeter, MonoCure, Multifil, Myritex, OptiStroke, Partnership+Plus, PatternJet, PatternPro, PCI, Pinnacle, Powder Pilot, Powercure, Precise Coat, Process Sentry, Pulse Spray, Quad Cure, RediCoat, Ready Coat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Signature, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Brand, SureFoam, SureMix, SureSeal, SureWrap, Swirl Coat, Tempus, TinyCure, Trade Plus, ThruWave, UltraMax, Ultrasmart, Universal, ValveMate, VersaDrum, VersaPail, Vista, Web Cure, and 2 Rings (Design) are trademarks of Nordson Corporation. Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners rights. All rights reserved

3 Table of Contents i Table of Contents Safety Safety Alert Symbols Responsibilities of the Equipment Owner Safety Information Instructions, Requirements, and Standards User Qualifications Applicable Industry Safety Practices Intended Use of the Equipment Instructions and Safety Messages Installation Practices Operating Practices Maintenance and Repair Practices Equipment Safety Information Equipment Shutdown General Safety Warnings and Cautions Other Safety Precautions First Aid Safety Labels and Tags Description Key Parts Solenoid Valve Dispensing Module EasyOn Feature Hose Connector/Filter Cordset Temperature Control Intended Use Auxiliary Devices and Spare Parts Installation Items Needed Installation Guidelines Mounting Hydraulic and Pneumatic Connections Unpacking and Inspection Mounting the Gun Mount a Gun on a New or Existing System Replace a Gun on an Existing System Making the Solenoid Valve Connections Connect the Air Supply Connect the Triggering Device to an SD Solenoid Valve Connect the Triggering Device to an SG Solenoid Valve Connecting the Hose Flushing the Gun

4 ii Table of Contents Operation Maintenance Cleaning Nozzles Inspecting the Gun Wiring Troubleshooting Troubleshooting Table Diagnostic Procedures (DPs) DP1. Check a Solenoid Valve DP2. Check for a Clogged Nozzle or Module DP3. Check a Heater DP4. Check an RTD Repair Replacing a Heater or RTD Replacing an SD Solenoid Valve Replacing an SG Solenoid Valve Parts Using the Illustrated Parts Lists Slim Single-Module Gun/SG Solenoid Valve Parts Slim Single-Module Gun/SD Solenoid Valve Parts Configurable Single-Module Gun/SD Solenoid Valve Parts Configurable Single-Module Gun/SG Solenoid Valve Parts Configurable Multi-Module Gun Parts SD Solenoid Valve Cables Saturn Nozzles Recommended Spare Parts Accessories and Supplies Technical Data Gun Specifications Nozzle Torque Specifications Cordset Pin Positions Dimensions Gun Configuration Code

5 MiniBlue Guns 1 MiniBlue Guns Safety Read this section before using the equipment. This section contains recommendations and practices applicable to the safe installation, operation, and maintenance (hereafter referred to as use ) of the product described in this document (hereafter referred to as equipment ). Additional safety information, in the form of task-specific safety alert messages, appears as appropriate throughout this document. WARNING: Failure to follow the safety messages, recommendations, and hazard avoidance procedures provided in this document can result in personal injury, including death, or damage to equipment or property. Safety Alert Symbols The following safety alert symbol and signal words are used throughout this document to alert the reader to personal safety hazards or to identify conditions that may result in damage to equipment or property. Comply with all safety information that follows the signal word. WARNING: Indicates a potentially hazardous situation that, if not avoided, can result in serious personal injury, including death. CAUTION: Indicates a potentially hazardous situation that, if not avoided, can result in minor or moderate personal injury. CAUTION: (Used without the safety alert symbol) Indicates a potentially hazardous situation that, if not avoided, can result in damage to equipment or property.

6 2 MiniBlue Guns Responsibilities of the Equipment Owner Equipment owners are responsible for managing safety information, ensuring that all instructions and regulatory requirements for use of the equipment are met, and for qualifying all potential users. Safety Information Research and evaluate safety information from all applicable sources, including the owner-specific safety policy, best industry practices, governing regulations, material manufacturer s product information, and this document. Make safety information available to equipment users in accordance with governing regulations. Contact the authority having jurisdiction for information. Maintain safety information, including the safety labels affixed to the equipment, in readable condition. Instructions, Requirements, and Standards Ensure that the equipment is used in accordance with the information provided in this document, governing codes and regulations, and best industry practices. If applicable, receive approval from your facility s engineering or safety department, or other similar function within your organization, before installing or operating the equipment for the first time. Provide appropriate emergency and first aid equipment. Conduct safety inspections to ensure required practices are being followed. Re-evaluate safety practices and procedures whenever changes are made to the process or equipment. User Qualifications Equipment owners are responsible for ensuring that users: receive safety training appropriate to their job function as directed by governing regulations and best industry practices are familiar with the equipment owner s safety and accident prevention policies and procedures receive, equipment- and task-specific training from another qualified individual NOTE: Nordson can provide equipment-specific installation, operation, and maintenance training. Contact your Nordson representative for information possess industry- and trade-specific skills and a level of experience appropriate to their job function

7 MiniBlue Guns 3 are physically capable of performing their job function and are not under the influence of any substance that degrades their mental capacity or physical capabilities Applicable Industry Safety Practices The following safety practices apply to the use of the equipment in the manner described in this document. The information provided here is not meant to include all possible safety practices, but represents the best safety practices for equipment of similar hazard potential used in similar industries. Intended Use of the Equipment Use the equipment only for the purposes described and within the limits specified in this document. Do not modify the equipment. Do not use incompatible materials or unapproved auxiliary devices. Contact your Nordson representative if you have any questions on material compatibility or the use of non-standard auxiliary devices. Instructions and Safety Messages Read and follow the instructions provided in this document and other referenced documents. Familiarize yourself with the location and meaning of the safety warning labels and tags affixed to the equipment. Refer to Safety Labels and Tags at the end of this section. If you are unsure of how to use the equipment, contact your Nordson representative for assistance. Installation Practices Install the equipment in accordance with the instructions provided in this document and in the documentation provided with auxiliary devices. Ensure that the equipment is rated for the environment in which it will be used and that the processing characteristics of the material will not create a hazardous environment. Refer to the Material Safety Data Sheet (MSDS) for the material. If the required installation configuration does not match the installation instructions, contact your Nordson representative for assistance. Position the equipment for safe operation. Observe the requirements for clearance between the equipment and other objects. Install lockable power disconnects to isolate the equipment and all independently powered auxiliary devices from their power sources. Properly ground all equipment. Contact your local building code enforcement agency for specific requirements. Ensure that fuses of the correct type and rating are installed in fused equipment.

8 4 MiniBlue Guns Contact the authority having jurisdiction to determine the requirement for installation permits or inspections. Operating Practices Familiarize yourself with the location and operation of all safety devices and indicators. Confirm that the equipment, including all safety devices (guards, interlocks, etc.), is in good working order and that the required environmental conditions exist. Use the personal protective equipment (PPE) specified for each task. Refer to Equipment Safety Information or the material manufacturer s instructions and MSDS for PPE requirements. Do not use equipment that is malfunctioning or shows signs of a potential malfunction. Maintenance and Repair Practices Perform scheduled maintenance activities at the intervals described in this document. Relieve system hydraulic and pneumatic pressure before servicing the equipment. De-energize the equipment and all auxiliary devices before servicing the equipment. Use only new factory-authorized refurbished or replacement parts. Read and comply with the manufacturer s instructions and the MSDS supplied with equipment cleaning compounds. NOTE: MSDSs for cleaning compounds that are sold by Nordson are available at or by calling your Nordson representative. Confirm the correct operation of all safety devices before placing the equipment back into operation. Dispose of waste cleaning compounds and residual process materials according to governing regulations. Refer to the applicable MSDS or contact the authority having jurisdiction for information. Keep equipment safety warning labels clean. Replace worn or damaged labels. Equipment Safety Information This equipment safety information is applicable to the following types of Nordson equipment: hot melt and cold adhesive application equipment and all related accessories pattern controllers, timers, detection and verification systems, and all other optional process control devices

9 MiniBlue Guns 5 Equipment Shutdown To safely complete many of the procedures described in this document, the equipment must first be shut down. The level of shut down required varies by the type of equipment in use and the procedure being completed. If required, shut down instructions are specified at the start of the procedure. The levels of shut down are: Relieving System Hydraulic Pressure Completely relieve system hydraulic pressure before breaking any hydraulic connection or seal. Refer to the melter-specific product manual for instructions on relieving system hydraulic pressure. De-energizing the System Isolate the system (melter, hoses, guns, and optional devices) from all power sources before accessing any unprotected high-voltage wiring or connection point. 1. Turn off the equipment and all auxiliary devices connected to the equipment (system). 2. To prevent the equipment from being accidentally energized, lock and tag the disconnect switch(es) or circuit breaker(s) that provide input electrical power to the equipment and optional devices. NOTE: Government regulations and industry standards dictate specific requirements for the isolation of hazardous energy sources. Refer to the appropriate regulation or standard. Disabling the Guns All electrical or mechanical devices that provide an activation signal to the guns, gun solenoid valve(s), or the melter pump must be disabled before work can be performed on or around a gun that is connected to a pressurized system. 1. Turn off or disconnect the gun triggering device (pattern controller, timer, PLC, etc.). 2. Disconnect the input signal wiring to the gun solenoid valve(s). 3. Reduce the air pressure to the gun solenoid valve(s) to zero; then relieve the residual air pressure between the regulator and the gun. General Safety Warnings and Cautions Table 1 contains the general safety warnings and cautions that apply to Nordson hot melt and cold adhesive equipment. Review the table and carefully read all of the warnings or cautions that apply to the type of equipment described in this manual. Equipment types are designated in Table 1 as follows:

10 6 MiniBlue Guns HM = Hot melt (melters, hoses, guns, etc.) PC = Process control CA = Cold adhesive (dispensing pumps, pressurized container, and guns) Equipment Type HM Table 1 General Safety Warnings and Cautions Warning or Caution WARNING: Hazardous vapors! Before processing any polyurethane reactive (PUR) hot melt or solvent-based material through a compatible Nordson melter, read and comply with the material s MSDS. Ensure that the material s processing temperature and flashpoints will not be exceeded and that all requirements for safe handling, ventilation, first aid, and personal protective equipment are met. Failure to comply with MSDS requirements can cause personal injury, including death. HM WARNING: Reactive material! Never clean any aluminum component or flush Nordson equipment with halogenated hydrocarbon fluids. Nordson melters and guns contain aluminum components that may react violently with halogenated hydrocarbons. The use of halogenated hydrocarbon compounds in Nordson equipment can cause personal injury, including death. HM, CA WARNING: System pressurized! Relieve system hydraulic pressure before breaking any hydraulic connection or seal. Failure to relieve the system hydraulic pressure can result in the uncontrolled release of hot melt or cold adhesive, causing personal injury. HM WARNING: Molten material! Wear eye or face protection, clothing that protects exposed skin, and heat-protective gloves when servicing equipment that contains molten hot melt. Even when solidified, hot melt can still cause burns. Failure to wear appropriate personal protective equipment can result in personal injury. Continued...

11 MiniBlue Guns 7 Equipment Type HM, PC General Safety Warnings and Cautions (contd) Table 1 General Safety Warnings and Cautions (contd) Warning or Caution WARNING: Equipment starts automatically! Remote triggering devices are used to control automatic hot melt guns. Before working on or near an operating gun, disable the gun s triggering device and remove the air supply to the gun s solenoid valve(s). Failure to disable the gun s triggering device and remove the supply of air to the solenoid valve(s) can result in personal injury. HM, CA, PC WARNING: Risk of electrocution! Even when switched off and electrically isolated at the disconnect switch or circuit breaker, the equipment may still be connected to energized auxiliary devices. De-energize and electrically isolate all auxiliary devices before servicing the equipment. Failure to properly isolate electrical power to auxiliary equipment before servicing the equipment can result in personal injury, including death. HM, CA, PC WARNING: Risk of fire or explosion! Nordson adhesive equipment is not rated for use in explosive environments and should not be used with solvent-based adhesives that can create an explosive atmosphere when processed. Refer to the MSDS for the adhesive to determine its processing characteristics and limitations. The use of incompatible solvent-based adhesives or the improper processing of solvent-based adhesives can result in personal injury, including death. HM, CA, PC WARNING: Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others and can damage to the equipment. HM CAUTION: Hot surfaces! Avoid contact with the hot metal surfaces of guns, hoses, and certain components of the melter. If contact can not be avoided, wear heat-protective gloves and clothing when working around heated equipment. Failure to avoid contact with hot metal surfaces can result in personal injury. HM CAUTION: Some Nordson melters are specifically designed to process polyurethane reactive (PUR) hot melt. Attempting to process PUR in equipment not specifically designed for this purpose can damage the equipment and cause premature reaction of the hot melt. If you are unsure of the equipment s ability to process PUR, contact your Nordson representative for assistance.

12 8 MiniBlue Guns Equipment Type HM, CA Warning or Caution CAUTION: Before using any cleaning or flushing compound on or in the equipment, read and comply with the manufacturer s instructions and the MSDS supplied with the compound. Some cleaning compounds can react unpredictably with hot melt or cold adhesive, resulting in damage to the equipment. HM CAUTION: Nordson hot melt equipment is factory tested with Nordson Type R fluid that contains polyester adipate plasticizer. Certain hot melt materials can react with Type R fluid and form a solid gum that can clog the equipment. Before using the equipment, confirm that the hot melt is compatible with Type R fluid. Other Safety Precautions Do not use an open flame to heat hot melt system components. Check high pressure hoses daily for signs of excessive wear, damage, or leaks. Never point a dispensing handgun at yourself or others. Suspend dispensing handguns by their proper suspension point. First Aid If molten hot melt comes in contact with your skin: 1. Do NOT attempt to remove the molten hot melt from your skin. 2. Immediately soak the affected area in clean, cold water until the hot melt has cooled. 3. Do NOT attempt to remove the solidified hot melt from your skin. 4. In case of severe burns, treat for shock. 5. Seek expert medical attention immediately. Give the MSDS for the hot melt to the medical personnel providing treatment.

13 MiniBlue Guns 9 Safety Labels and Tags Figure 1 illustrates the location of the product safety labels and tags affixed to the equipment. Table 2 provides an illustration of the hazard identification symbols that appear on each safety label and tag, the meaning of the symbol, or the exact wording of any safety message Figure 1 Safety labels and tags

14 10 MiniBlue Guns Table 2 Safety Labels and Tags Item Part Description 1. N/A 2. N/A WARNING: Hot surface! Before touching the gun body, allow the gun to cool, or wear heat-protective gloves. Failure to allow the gun body to cool or to wear heat-protective gloves may cause personal injury WARNING: Disconnect power and remove system pressure before disassembly or maintenance. Failure to follow these instructions may result in serious personal injury WARNING: Fire, injury or equipment damage can result if cleanout materials do not meet the following requirements: 1. Minimum flash point to be 550F (288C). 2. Liquid and vapor to be non-toxic at use temperature in equipment. 3. Chemical reactions with adhesive and equipment materials must not be violently heat producing. 4. Cleanout material must not corrode or otherwise weaken equipment materials CAUTION: This gun is RTD (resistance temperature detector) controlled. Prior to operation and before changing adhesive, consult instruction manual for changing operating temperature. Failure to follow instructions may result in personal injury or property damage CAUTION: This equipment is factory tested with Nordson type R fluid containing Polyester Adipate plasticizer. Certain adhesives may react with the type R fluid residue to form solid gum which can be difficult to remove. To avoid equipment damage check with adhesive supplier regarding compatibility and cleanout procedure before putting adhesive into the system.

15 MiniBlue Guns 11 Description Nordson MiniBlue automatic guns apply thermoplastic hot melt adhesive to a product, providing uniform bead deposition and improved cutoff when used with aggressive or hard-to-dispense adhesives. Their air-open, air-close dispensing modules allow high cycle speeds and their compact size allows them to fit between the flaps of most cartons. MiniBlue guns are available in a slim,18-mm (0.71-in.) single-module design and in a variety of configurable designs, including single-module and multi-module configurations. MiniBlue guns are manufactured according to the design choices made at the time of order placement. Refer to Gun Configuration Code under Technical Data at the end of this manual for more information. Figure 2 shows some typical MiniBlue guns. Figures 3 and 4 show the key parts of two typical MiniBlue guns. NOTE: The illustrations in this manual depict typical MiniBlue guns. Your gun may differ in appearance. 1 Figure 2 Typical MiniBlue guns 1. Slim single-module gun with SD solenoid valve 2 2. Two-module configurable gun with SD solenoid valves Three-module configurable gun with SG solenoid valves

16 12 MiniBlue Guns Key Parts Figure 3 Key parts of a slim single-module MiniBlue gun 1. Cordset 5. Filter (integrated) 2. Solenoid valve 6. Body 3. Mounting bracket 7. Module 4. Hose connector 8. Muffler

17 MiniBlue Guns Figure 4 5 Key parts of a typical configurable MiniBlue gun (two-module gun shown) 1. Cordset 2. Solenoid valve 3. Mounting bracket 4. Hose connector/inline filter 5. Body 6. Module 7. Muffler

18 14 MiniBlue Guns Solenoid Valve See Figure 5. MiniBlue guns use either small SD solenoid valves or large SG solenoid valves: If the production line speed is 90 m/min (295 ft/min) or less, either SD or SG solenoid valves may be used. If the production line speed is greater than 90 m/min (295 ft/min), only SG solenoid valves may be used. Solenoid valves may be configured for independent, common, or programmed module actuation, as described in Table 3. Table 3 Types of Module Air Actuation Type of Actuation Description Independent One solenoid valve directly actuates one module Common One solenoid valve actuates all modules. NOTE: SD solenoid valves may not be used in common air gun configurations. Programmed Two solenoid valves actuate actuate two groups (left and right) of modules NOTE: For the best module performance in intermittent applications, Nordson Corporation recommends the use of one solenoid valve per module (independent actuation). Module performance will be sacrificed proportionately as more modules are controlled by a single solenoid valve (common or programmed actuation) Figure 5 Solenoid valve types 1. SD solenoid valve 2. SG solenoid valve

19 MiniBlue Guns 15 Dispensing Module See Figure 6. MiniBlue guns use either reduced-cavity or ball-and-seat dispensing modules: Reduced-cavity modules have an integral nozzle and are virtually self-cleaning. The modules are available with 0.20, 0.30, 0.41, and 0.51 mm ( , 0.016, and in.) nozzle orifice sizes. Ball-and-seat modules are used in combination with Saturn nozzles, allowing easier change-out of nozzle sizes and eliminating the need to stock multiple reduced-cavity modules with different orifice sizes. A MiniBlue gun may have 1 8 modules. Air is supplied constantly to a module through a solenoid valve. When the gun is not being triggered, air will flow through the module s air-close port to keep the module needle on its seat. When triggered, the solenoid valve will direct air into the air-open port, lifting the needle from its seat to dispense the adhesive Figure 6 Module types 1. Ball-and-seat module 2. SureBead module 3. SureBead nozzle EasyOn Feature All MiniBlue gun modules use the EasyOn feature. The EasyOn feature on the module, mates with the EasyOn feature on the gun body. The EasyOn feature allows the module to be installed onto the gun body, regardless of the orientation of the gun body. EasyOn feature on the gun body

20 16 MiniBlue Guns Hose Connector/Filter See Figure 7. All MiniBlue guns have a straight, 45-degree, or 90-degree hose connector and either an integrated or an inline Saturn filter. Saturn filters use a configurable screen. On slim single-module guns, the filter is integral to the gun and is located just below the hose connector. On single- and multi-module configurable guns, the filter is inline with the hose connector Figure 7 Location of hose connectors and Saturn filters on different gun configurations 1. Hose connector (45 degree shown) 2. Integrated filter (slim single-module gun) 3. Hose connector/inline filter (45 degree shown)

21 MiniBlue Guns 17 Cordset The gun cordset may be positioned on either the right or left end, or on the right or left side of the back of configurable multi-module guns. Only top mounted cordsets are available on slim guns. See Figure 8. Cordsets are available in water-resistant and standard versions Figure 8 Cordset types 1. T-style cordset 2. Water-resistant cordset Temperature Control All MiniBlue guns use 120-ohm nickel resistance temperature detectors (RTDs) for precise temperature sensing and for gun temperature control to within ±0.5 C (1.0 F) of a setpoint temperature. Intended Use MiniBlue guns are specifically designed for industrial applications that require the deposition of a precisely controlled bead of hot melt material onto a moving substrate. The guns are designed to be rigidly mounted, pneumatically operated, and triggered by a Nordson-approved, electrically controlled solenoid valve. MiniBlue guns are designed for use with Nordson melters and hoses. Auxiliary Devices and Spare Parts MiniBlue guns should only be connected to approved auxiliary devices. Use only new Nordson replacement parts or approved factory refurbished parts.

22 18 MiniBlue Guns Installation Guns are installed using the following six-step process: unpack and inspect mount connect the air supply connect the hose flush install nozzles (if applicable) Guns ordered with special options may require additional installation steps that are not described here. NOTE: Nozzles must be ordered separately. Refer to Parts for nozzle part numbers. Items Needed To ensure a smooth installation, have the following items on hand: personal protective equipment for working with hot adhesive product manuals for associated equipment (melter, hose, etc.) device to lift and position the applicator mounting equipment, such as a mounting rod, appropriate for the parent machine wiring and 24 VDC power supply for the solenoid valve air pressure regulator and air line tubing (10 mm or 3 / 8 in. internal diameter or larger) NOTE: Tubing with an internal diameter smaller than 10 mm or 3 / 8 in. will negatively impact the gun s performance. automatic gun hose set of standard and metric hex-head wrenches flat-blade and Phillips-head screwdrivers drain pans and waste containers suitable for waste adhesive O-ring lubricant anti-seize lubricant PTFE tape

23 MiniBlue Guns 19 Installation Guidelines Use the following installation guidelines for optimum gun performance. Mounting Mount the gun such that the nozzle will be as close as possible to the substrate, but at a distance that works best for your application. Typically, the minimum distance is two times the diameter of the nozzle orifice. Ensure that the mounting location provides sufficient clearance around the rear or sides of the gun to allow for removal of the manifold covers. Mount the gun on a rigid support that is isolated from external vibrations and that prevents the gun from rotating. Insulate the gun from the support using the insulator provided with the gun. Hydraulic and Pneumatic Connections Use only one fitting to connect a hose to a hose connector on the gun. Insulate hose-to-gun joints. Insulating cuffs may be ordered separately. Refer to Parts. Use only clean, dry, non-lubricated air. Ensure that the plant air supply and regulator provide a minimum of 4 bar (58 psig) to the gun solenoid valve. Unpacking and Inspection 1. Carefully unpack the gun. 2. Inspect the gun and inventory the contents of the shipping package. Guns are shipped fully assembled and typically include the following components: mounting clamp module(s) solenoid valve(s) Guns ordered with optional features may be shipped with additional components.

24 20 MiniBlue Guns Mounting the Gun This section describes the following gun-mounting options: mounting a gun on a new or existing system replacing a gun on an existing system The configuration of your equipment and production line may require a variation in the mounting options described in this section. Regardless of the mounting method used, follow the guidelines provided in Installation Guidelines. Mount a Gun on a New or Existing System 1. See Figure 9. Slide the gun mounting clamp(s) onto a 12-mm, 13-mm, or 0.5-in. mounting bar, or disassemble the clamp(s) and reassemble them (with the gun and insulators) onto the mounting bar. Ensure that the insulators are placed between the manifold and the clamp(s). 2. Securely tighten the mounting clamp(s). 3. Go to Making the Solenoid Valve Connections. 1 (12 mm, 13 mm, or 0.5 in. diameter) 3 2 Figure 9 Mounting a gun using the mounting clamp (slim single-module gun shown) 1. Mounting bar 3. Insulator 2. Mounting clamp

25 MiniBlue Guns 21 Replace a Gun on an Existing System NOTE: MiniBlue guns are preassembled with a Nordson-approved, performance-matched solenoid valve. If a MiniBlue gun requires replacement, the entire gun assembly (the gun and the solenoid valve) must be replaced as a single unit. NOTE: The distance from the mounting rod centerline and the nozzle tip is different on a slim single-module gun and a single-module configurable gun, as shown in Figure 10. If you are replacing a single-module gun, be sure to the replace the correct gun style. 1. Relieve system hydraulic pressure and disable the gun to be replaced. Refer to Safety. 2. Disconnect the hose from the gun both electrically and hydraulically. 3. Separate the existing gun from its mounting. If a mounting clamp will not be reused, remove it from the mounting bar. 4. Mount the new gun and insulator onto the existing mounting clamp (or rod) or disassemble a new gun s mounting clamp and then reassemble the clamp (with the gun and insulator) onto the existing mounting bar. Tighten the clamp securely. 5. Go to Making the Solenoid Valve Connections mm (3.1 in.) (2.93 in.) Figure (2.25 in.) 50.8 mm (2.0 in.) 1 2 Difference in mounting-rod-to-nozzle centerline distances on a slim single-module gun (1) and a configurable single-module gun (2)

26 22 MiniBlue Guns Making the Solenoid Valve Connections Solenoid valves must be connected to: an air supply a triggering device, such as a pattern controller or timer Be sure to refer to the correct triggering device connection procedure for the solenoid valve on your gun. Connect the Air Supply Connect a clean, dry, non-lubricated air supply to the air inlet on the solenoid valves. The air line tubing should have a 10-mm or 3 / 8 -in. or larger internal diameter. Tubing with an internal diameter smaller than 10 mm or 3 / 8 in. will negatively impact the gun s performance. NOTE: Refer also to Installation Guidelines earlier in this section and, if applicable, to the instructions supplied with the solenoid valve. Connect the Triggering Device to an SD Solenoid Valve See Figure 11. Connect the SD solenoid valve cable to the solenoid valve and to the triggering device. NOTE: Refer to Parts for the 90-degree cable part number Figure 11 Removing the cable connection from an SD solenoid valve 1. SD solenoid valve cable (straight) 2. SD solenoid valve cable (90-degree) 3. SD solenoid valve 4. Air inlet

27 MiniBlue Guns 23 Connect the Triggering Device to an SG Solenoid Valve 1. See Figure 12. Remove the solenoid valve cable connection. Save the gasket that is positioned between the cable connection and the valve Figure 12 Removing the cable connection from an SG solenoid valve 1. Cable connection screw 3. Gasket 2. Cable connection CAUTION: Do not attempt to pry the cable connection out of the housing. Doing so can damage the electrical connection pins. 2. See Figure 13. Gently press against the edge of one of the cable connection retaining prongs to remove the cable connection from the housing.

28 24 MiniBlue Guns Making the Solenoid Valve Connections (contd) A Figure 13 Removing the cable connection from the housing CAUTION: Solenoid valves must be rated for the output voltage of the triggering device. Make sure the ratings match V Solenoid valve terminal block positions 3. Thread a mm 2 (18 22 AWG) three-conductor cable through the housing strain relief and then connect the positive and negative leads to terminals 1 and 2 (polarity does not matter) and connect the ground wire to the ground terminal. The terminal positions are marked on the bottom of the cable connection. 4. Snap the cable connection back into its housing. 5. Align the gasket on the cable connection housing, plug the cable connection into the solenoid valve, and secure it with the screw removed earlier. 6. Connect the three-conductor cable to the triggering device. Refer to the instructions that came with the triggering device. 7. Go to Connecting the Hose.

29 MiniBlue Guns 25 Connecting the Hose NOTE: Refer to the user s guide shipped with the hose for detailed hose installation guidelines. 1. Connect the hose to the gun as shown in the following table. Gun Type Hose Connection Procedure Figure Slim singlemodule gun Connect the hose to the straight, 45-degree, or 90-degree hose connector. Use two wrenches to tighten the hose fitting. 14 Single- or multi-module configurable gun Connect the hose to the straight, 45-degree, or 90-degree inline Saturn filter. Use two wrenches to tighten the hose fitting See Figure 14 or 15 as applicable. Connect the gun cordset to the hose. 3. Connect the hose to the melter. Refer to the hose user s guide and/or the melter product manual as needed. 4. Go to Flushing the Gun Figure 14 Connecting the hose to a slim single-module gun Figure 15 Connecting the hose to a single- or multi-module configurable gun

30 26 MiniBlue Guns Flushing the Gun Before the gun is placed into operation, it must be flushed of foreign material. CAUTION: This equipment is factory tested with Nordson Type R fluid containing polyester adipate plasticizer. Certain adhesives may react with the Type R fluid residue to form a solid gum that can be difficult to remove. Consult with your adhesive supplier to determine the compatibility of your adhesive with Type R fluid. 1. Disconnect or turn off the solenoid valve triggering device. 2. Start the melter and heat the system to the operating temperature and pressure required for the adhesive being used. Refer to the melter product manual and the instructions provided with the adhesive as needed. 3. Place a drain pan under the gun. 4. Remove the nozzle(s) from the gun. Refer to the nozzle removal procedures under Cleaning Nozzles later in this manual as needed. 5. Dispense adhesive from the gun by manually triggering the solenoid valve(s). 6. Stop dispensing when the adhesive flow is clear and free of foreign material. 7. Check for leaks between the gun, hose, and melter. 8. Install the gun nozzles. Refer to the nozzle installation procedures under Cleaning Nozzles later in this manual as needed. Operation Refer to the melter product manual for operating instructions. WARNING: MiniBlue gun modules operate as air-open, air-close valves. The loss or elimination of air pressure to the gun solenoid valve without a corresponding reduction in system hydraulic pressure may cause the gun modules to remain open.

31 MiniBlue Guns 27 Maintenance Table 4 provides the recommended schedule for gun maintenance. Detailed procedures for weekly and semi-annual maintenance tasks are provided in the remainder of this section. Table 4 Gun Maintenance Schedule Frequency Task Notes Daily Remove hot melt and char from the exterior of the gun assembly. Weekly Clean the gun nozzle(s). Refer to Cleaning Nozzles. A, B Semi-annually Inspect the gun wiring. Refer to Inspecting the Gun Wiring. As needed Replace the filter. Refer to the instructions supplied with the replacement filter. NOTE A: Nordson recommends the use of a nozzle cleaning kit. B: Process-specific nozzle performance history may indicate the need for more or less frequent nozzle cleaning.

32 28 MiniBlue Guns Cleaning Nozzles Gun nozzles may become clogged when char, a by-product of overheating the hot melt, becomes lodged in the nozzle. 1. Heat the gun to operating temperature. 2. Disable the gun. Refer to Safety. 3. Remove the nozzles. Refer to Table 5. Nozzle Type Reduced cavity Table 5 Nozzle Removal Procedures Nozzle Removal Procedure Use a wrench to loosen the nozzle and then remove the nozzle by hand. Remove the nozzle O-ring. Do not touch the needle. Saturn Use two wrenches one on the nozzle retainer and one on the nozzle to loosen the nozzle; then remove the nozzle by hand. WARNING: Risk of fire. Do not heat Nordson Type R fluid above 245 C (475 F). Use only an industrial grade, regulated, electrical heating device that is designed to heat industrial fluids. Personal injury or property damage can result if Type R cleaning fluid is heated with an open flame or in an unregulated heating device. 4. Soak the nozzles in Nordson Type R cleaning fluid that has been heated above the melting point of the adhesive, to a maximum of 177 C (350 F). 5. Remove the nozzles from the cleaning fluid.

33 MiniBlue Guns 29 CAUTION: Use the correct size precision pin probe to clean Nordson nozzles. The use of non-precision or incorrectly sized probes may damage the nozzle. The Nordson nozzle cleaning kit (part ) contains a variety of probe sizes. 6. See Figure 16. At the outlet of each nozzle, insert a correctly sized cleaning probe. 7. With a clean cloth, firmly grip the cleaning probe, then pull the probe out of the nozzle, wiping the probe clean. Figure 16 Cleaning a Nozzle A 8. If the spring-guide washer and seal-retaining spring fell out of the gun module when the nozzle was removed, reinstall them in the orientation shown in Figure 17.

34 30 MiniBlue Guns Cleaning Nozzles (contd) A Figure 17 Orientation of spring-guide washer and seal retaining spring 1. Gun module 2. Spring-guide washer 3. Seal-retaining spring 9. Reinstall the nozzles. Refer to Table 6. Nozzle Type Reduced cavity Table 6 Nozzle Installation Procedures Nozzle Installation Procedure Lubricate the nozzle O-ring and install the nozzle using a torque wrench. Tighten to Nm (18 24 in.-lb). NOTE: The O-ring part number is Saturn Thread the nozzle onto the module threads by hand; then use a regular wrench and a torque wrench to tighten the nozzle to 4.5 Nm (40 in.-lb). 10. Restore the system to normal operation. Inspecting the Gun Wiring 1. De-energize the system. Refer to Safety. 2. Remove the manifold cover. 3. Check the internal gun wiring for signs of damage and the cable connection for tightness. 4. Reinstall the manifold cover.

35 MiniBlue Guns 31 Troubleshooting WARNING: Risk of personal injury. This equipment contains pressurized hot melt material and high voltage circuits. Read the Safety information provided in this document before completing any troubleshooting procedure. Failure to observe safety messages and hazard-avoidance procedures can result in personal injury, including death. Troubleshooting Table The following table lists the gun problems that are most likely to occur, the possible causes of each problem, and steps for corrective action. Where applicable, cross-references are made to expanded diagnostic procedures (DPs) provided later in this section or to other sections of this manual. Problem Possible Cause Corrective Action 1. No adhesive flow Adhesive level low Add adhesive. from a single gun module or from any module on a multi-module gun No input power Connect power to the melter and auxiliary devices. Ensure that all disconnect switches or circuit breakers are on. Melter, hose, or gun temperature setting too low System not at operating temperature Insufficient air pressure to melter piston pump (piston pump melters) Melter motor not operating (gear pump melters) No air supply to solenoid valve Solenoid valve failed Hose clogged Nozzle clogged Adhesive in air section of module Module failed Adjust the setting. Refer to the melter product manual. Verify that the system ready light is on and that the adhesive is molten. Adjust the pump air pressure. Check the motor operation. Refer to the melter product manual. Check the plant air supply pressure. Check the solenoid valve and replace if necessary. Refer to DP1. Replace the hose. Check the nozzle. Refer to DP2. Replace the module. Refer to the instructions provided with the module. Replace the module. Refer to the instructions provided with the module. Continued...

36 32 MiniBlue Guns Troubleshooting Table (contd) Problem Possible Cause Corrective Action 1. No adhesive flow from a singlemodule gun or from any module of a multi-module gun (contd.) Dirty or faulty triggering device Clean or replace the triggering device. 2. No adhesive flow from some modules in a multi-module gun 3. Uncontrolled adhesive flow from module 4. Adhesive or air flows from bleed hole 5. Modules not triggering at the same time on multi-module gun 6. Gun fails to heat or underheats Faulty encoder Nozzle clogged Module failed Hydraulic pressure too high Hydraulic pressure too high and gun air pressure lost Module failed open Solenoid valve ported to manifold backwards or failed open Air or adhesive seals failed Module failed Insufficient gun air pressure No power Gun temperature setpoint too low Gun heater failed (open or short) Gun RTD failed (open or short) Test the encoder and replace if defective. Check the nozzle. Refer to DP2. Replace the module. Refer to the instructions provided with the module. Decrease the system hydraulic pressure. Stop the melter pump and restore the air pressure to the gun. Replace the module. Refer to the instructions provided with the module. Correct the solenoid valve porting or replace the solenoid valve. If applicable, refer to the instructions supplied with the solenoid valve. Replace the module. Refer to the instructions provided with the module. Replace the module. Refer to the instructions provided with the module. Increase the gun air pressure. Check that the melter is on. Refer to the melter product manual. Adjust the temperature setpoint. Refer to the melter product manual. Check for an open heater circuit. Refer to DP3. Check the RTD resistance. Refer to DP4. Continued...

37 MiniBlue Guns 33 Problem Possible Cause Corrective Action 7. Gun overheats Tank, hose, or gun temperature setpoint too high Gun RTD shorted (melter should shut down) Short in heater control circuit 8. Adhesive leaking between reduced-cavity module body and nozzle Damaged O-ring or nozzle Adjust the setpoint. Refer to the melter product manual. Check the RTD resistance. Refer to DP4. Troubleshoot the melter. Refer to the melter product manual. Replace the O-ring or nozzle. Diagnostic Procedures (DPs) The following diagnostic procedures (DPs) are referenced in the Troubleshooting Table. DP1. Check a Solenoid Valve 1. Place the system into operation. 2. Trigger the gun using the timer or pattern controller: Adhesive flows normal indication. Return to the Troubleshooting Table. No adhesive flow go to step Manually trigger the gun at the solenoid valve: Adhesive flows normal indication. Return to the Troubleshooting Table. No adhesive flow go to step Check the solenoid valve coil for continuity: Continuity okay normal indication. Return to the Troubleshooting Table. No continuity failed solenoid valve. Replace the solenoid valve. NOTE: Verify that the solenoid valve being used has a rated service temperature above 85 C (185 F).

38 34 MiniBlue Guns DP2. Check for a Clogged Nozzle or Module 1. Disable the gun. Refer to Safety. 2. Remove the nozzle. Refer to Cleaning Nozzles for the nozzle-removal procedure. 3. Place the gun back into operation. 4. Trigger the gun: Adhesive flows normal indication. Clean the nozzle. Refer to Maintenance. No adhesive flow the module is clogged. Replace the module. Refer to Repair. DP3. Check a Heater 1. Disable the gun. Refer to Safety. 2. Unplug the gun cordset from the hose. 3. See Figure 18. Test for continuity across the heater circuit (pins 1 and 2): Continuity okay normal indication. Return to the Troubleshooting Table. No continuity the heater is defective. Replace the heater. Refer to Repair. HEATER HEATER RTD RTD GND A Figure 18 Gun cordset pin positions