World Gun Series Customer Product Manual Issued 11/03 NORDSON CORPORATION DULUTH, GEORGIA USA www.nordson.com
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: http://www.nordson.com. Address all correspondence to: Nordson Corporation Attn: Customer Service 11475 Lakefield Drive Duluth, GA 30097 Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2002. 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. 2002 All rights reserved. Trademarks AccuJet, AquaGuard, Asymtek, Automove, Autotech, Blue Box, CF, CanWorks, Century, Clean Coat, CleanSleeve, CleanSpray, Compumelt, Control Coat, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, Durafiber, Durasystem, Easy Coat, Easymove Plus, Econo-Coat, EPREG, ETI, Excel 2000, Flex-O-Coat, FlexiCoat, Flexi-Spray, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Helix, Horizon, Hose Mole, Hot Shot, Hot Stitch, Isocoil, Isocore, Iso-Flo, JR, KB30, Little Squirt, Magnastatic, MEG, Meltex, MicroSet, Millennium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OmniScan, Opticoat, OptiMix, Package of Values, Patternview, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, PRX, RBX, Rhino, S. design stylized, Saturn, SC5, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Spray Squirt, Spraymelt, Super Squirt, Sure Coat, System Sentry, Tela-Therm, Trends, Tribomatic, UniScan, UpTime, Veritec, Versa-Coat, Versa-Screen, Versa-Spray, Walcom, Watermark, and When you expect more. are registered trademarks of Nordson Corporation. ATS, AeroCharge, Auto-Flo, AutoScan, BetterBook, Chameleon, CanNeck, Check Mate, Colormax, Control Weave, Controlled Fiberization, Coolwave, CPX, Dry Cure, E-Nordson, EasyClean, Eclipse, Equi=Bead, Fill Sentry, Fillmaster, Gluie, Heli-flow, Ink-Dot, Iso-Flex, Kinetix, Lacquer Cure, Maxima, MicroFin, Minimeter, Multifil, Origin, PermaFlo, PluraMix, Powder Pilot, Powercure, Primarc, Process Sentry, PurTech, Pulse Spray, Ready Coat, Select Series, Sensomatic, Shaftshield, SheetAire, Spectral, Spectronic, Spectrum, Summit, Sure Brand, Sure Clean, Sure Max, Swirl Coat, Tempus, Tracking Plus, Trade Plus, Universal, Vista, Web Cure, and 2 Rings (Design) are trademarks of Nordson Corporation. 2003 Nordson Corporation
Table of Contents i Table of Contents Safety......................................................... 1 Safety Alert Symbols............................................ 1 Responsibilities of the Equipment Owner........................... 2 Safety Information............................................ 2 Instructions, Requirements, and Standards...................... 2 User Qualifications........................................... 3 Applicable Industry Safety Practices............................... 3 Intended Use of the Equipment................................. 3 Instructions and Safety Messages.............................. 3 Installation Practices.......................................... 4 Operating Practices........................................... 4 Maintenance and Repair Practices.............................. 5 Equipment Safety Information.................................... 5 Equipment Shutdown......................................... 5 General Safety Warnings and Cautions.......................... 6 Other Safety Precautions...................................... 9 First Aid..................................................... 10 Safety Labels and Tags.......................................... 10 Description.................................................... 12 Intended Use................................................... 16 Auxiliary Devices and Spare Parts................................ 16 Gun Configuration Code......................................... 16 Installation.................................................... 18 Installation Guidelines........................................... 18 Mounting.................................................... 18 Hydraulic and Pneumatic Connections.......................... 19 Solenoid Valves.............................................. 19 Unpacking and Inspection........................................ 19 Mounting the Gun............................................... 20 Mount a Gun on a New or Existing System....................... 20 Replace a Gun on an Existing System........................... 21 Making the Solenoid Valve Connections........................... 22 Install Solenoid Valves (If Applicable)........................... 22 Connect the Air Supply........................................ 22 Connect the Triggering Device................................. 23 Connecting the Hose............................................ 24 Flushing the Gun............................................... 25 Installing Nozzles............................................... 26 2003 Nordson Corporation
ii Table of Contents Operation..................................................... 27 Gun Module Adjustments...................................... 27 Adjusting H-200 Zero Cavity Modules............................. 27 Adjusting H-400 Modules........................................ 29 Operating Under 30 bar (450 psi) Hydraulic Pressure............. 29 Compensating for Low Gun Air Pressure........................ 29 Returning an H400 Gun Module to the Factory Setting............ 30 Troubleshooting............................................... 31 Troubleshooting Table........................................... 31 Diagnostic Procedures (DPs)..................................... 33 DP1. Check a Solenoid Valve................................... 33 DP2. Check for a Clogged Nozzle or Module..................... 34 DP3. Check Module Operation (All Guns Except H-440)............ 34 DP4. Check a Heater.......................................... 35 DP5. Check an RTD.......................................... 35 Maintenance................................................... 36 Cleaning Nozzles............................................... 37 Inspecting the Gun Wiring........................................ 39 Repair........................................................ 40 Replacing an RTD or Heater..................................... 40 Access the RTD or Heater..................................... 40 Replace the RTD or Heater..................................... 41 Restore the System to Normal Operation......................... 42 Replacing a Module............................................. 42 Parts.......................................................... 44 Gun-Specific Parts.............................................. 44 Recommended Spare Parts...................................... 44 Accessories and Supplies........................................ 44 Technical Data................................................. 45 Gun Specifications.............................................. 45 Torque Specifications............................................ 45 Cordset Wiring Diagram......................................... 45 Dimensions.................................................... 45 2003 Nordson Corporation
World Gun Series 1 World Gun Series 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. 2003 Nordson Corporation
2 World Gun Series 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. 2003 Nordson Corporation
World Gun Series 3 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 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. 2003 Nordson Corporation
4 World Gun Series 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. 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. 2003 Nordson Corporation
World Gun Series 5 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 www.nordson.com 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 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. 2003 Nordson Corporation
6 World Gun Series 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: HM = Hot melt (melters, hoses, guns, etc.) PC = Process control CA = Cold adhesive (dispensing pumps, pressurized container, and guns) 2003 Nordson Corporation
World Gun Series 7 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... 2003 Nordson Corporation
8 World Gun Series General Safety Warnings and Cautions (contd) Equipment Type HM, PC 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. CA WARNING: Risk of fire or explosion! Nordson cold 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. Continued... 2003 Nordson Corporation
World Gun Series 9 Equipment Type HM Table 1 General Safety Warnings and Cautions (contd) Warning or Caution 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. HM, CA 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. 2003 Nordson Corporation
10 World Gun Series 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. 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. 3 1 6 5 4 2 4209001A Figure 1 Safety labels and tags 2003 Nordson Corporation
World Gun Series 11 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. 3. 600 137 WARNING: Disconnect power and remove system pressure before disassembly or maintenance. Failure to follow these instructions may result in serious personal injury. 4. 243 352 WARNING: Fire, injury, or equipment damage can result if cleanout materials do not meet the following requirements: 1. Minimum flashpoint 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. 5. 600 103 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. 6. 243 352 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. 2003 Nordson Corporation
12 World Gun Series Description This manual provides information about World Gun Series (WGS) modular hot melt guns. WGS guns are configurable, which means that each gun is constructed according to specific choices made when the gun was ordered. Each gun has a configuration code that represents the configuration of the gun. Refer to Gun Configuration Code later in this section to determine the configuration of a gun based on its configuration code. WGS guns are characterized by the type of module installed on the gun manifold. Figure 2 shows the key parts of a typical WGS gun and Table 3 summarizes the differences between the WGS gun types. NOTE: WGS guns are available in multiple-module and water-wash designs. 1 2 6 3 4 5 Figure 2 Key parts of a WGS gun (H-442 gun shown) 1. Solenoid valve 4. Manifold 2. Cordset 5. Nozzle (sold separately) 3. Mounting bracket 6. Module Note: Hose connectors are located on the back of the gun. 4209002A 2003 Nordson Corporation
World Gun Series 13 Table 3 Summary of WGS Gun Module Types Module Type Characteristics Description H-200 H-200 standard module, adjustable (allows changes in bead placement) Air-open, spring-close operation Accommodates Saturn single-orifice and right-angle nozzles H-200 guns can operate at speeds that exceed 4,500 cycles per minute with conventional hot melt adhesives. The ball and seat design assures clean cutoff at the nozzle. H-200 guns are suitable for low-to-medium speed applications. H-200 rightangle H-200, right-angle module, adjustable (allows changes in bead placement) Air-open, spring-close operation Accommodates integrated right-angle module nozzles H-200 right-angle guns provide 90-degree application flexibility for low-to-medium speed applications. Continued... 2003 Nordson Corporation
14 World Gun Series Description (contd) H-200 zero cavity H-200 reduced cavity Table 3 Summary of WGS Gun Module Types (contd) Gun Type Characteristics Description H-200 zero cavity module with micro-adjuster Air-open, spring-close operation Available in six orifice sizes H-200 reduced cavity module, adjustable (allows changes in bead placement) Air-open, spring-close operation Available in four orifice sizes H-200 zero cavity guns are designed for critical applications that require consistent no-clog/no-drip operation, precise bead placement, and extrusion control. The close-tolerance, matched nozzle-and-needle assembly in these guns eliminates the formation of minute adhesive pockets that can lead to nozzle clogging, drool, and adhesive stringing. The movement of the needle within the nozzle creates a self-cleaning action, minimizing blockages and reducing maintenance. Applications for these guns include high-speed cartoning, case sealing, cap lining, nonwovens side seaming and elastic attachment, bonding, and gasketing. Zero cavity guns feature a patented micro-adjust module. A micrometer adjustment screw at the top of the module can reduce adhesive flow by up to 30 percent. Additionally, minor variations in bead position can be achieved via a load adjustment mechanism. These adjustments are especially beneficial in high-speed, multi-module gun applications. H-200 reduced cavity guns have an integrated nozzle-and-needle assembly that results in self-cleaning action and sharp cutoff. When used in low-to-medium speed applications, reduced cavity guns provide clog-free/minimum drip operation, uniform beads, and consistent flow over a wide range of temperatures. Continued... 2003 Nordson Corporation
World Gun Series 15 Table 3 Summary of WGS Gun Module Types (contd) Gun Type Features Application H-400 H-400 standard module, spring-tension adjustable (not stroke-adjustable) Air-open, spring-close operation Accommodates Saturn single-orifice and right-angle nozzles H-400 guns provide double the service life of H-200 guns and deliver exceptional adhesive cut-off/ minimum-drip operation for medium-to-high speed applications. The factory-set stroke and precision components eliminate the need for operator adjustment of the module for consistent bead pattern placement. H-440 H-440 standard module, non-adjustable Air-open, air-close operation Preinstalled solenoid valve Accommodates Saturn single-orifice and right-angle nozzles H-440 guns provide faster speeds than H-400 guns (because of the air-open, air-close operation), double the service life of H-200 guns, and deliver exceptional accuracy for high-speed, high-quality applications. The factory-set stroke and precision components eliminate the need for operator adjustment of the module for consistent bead pattern placement. H-440 guns are recommended for use with adhesives that have a viscosity greater than 1,250 cps. Continued... 2003 Nordson Corporation
16 World Gun Series Description (contd) Table 3 Summary of WGS Gun Module Types (contd) Gun Type Features Application SureBead A High quality patterns with virtually clog-free operation, even when using difficult to machine low and medium viscosity adhesives Maximum bead deposition capability Air-open, air-close operation Colored rings on the removable nozzle easily identify seat type and orifice sizes Nozzles are interchangeable change orifice sizes without removing the module from the gun Nozzle tip is maintained resulting in cleanly applied beads and better product seals SureBead modular hot melt guns are designed for easy flushing by removing the nozzle from the module. Nozzles used with a SureBead gun are designed to perform similar in function to reduced cavity and zero cavity nozzles. SureBead guns are designed to dispense packaging grade adhesives. Do not dispense polyurethane reactive or polyamide hot melt materials. Intended Use WGS guns are specifically designed for industrial applications that require the deposition of a precisely controlled stream of hot melt material onto a moving substrate. The guns are designed to be rigidly mounted, pneumatically operated, and triggered by an electrically controlled solenoid valve. WGS guns are designed for use with Nordson melters and hoses. Auxiliary Devices and Spare Parts WGS guns should only be connected to approved auxiliary devices. Use only new Nordson replacement parts or approved factory refurbished parts. Gun Configuration Code WGS guns are configurable, which means that each gun is constructed according to specific choices made when the gun was ordered. A configuration code that represents the configuration of the gun is stamped on the gun identification plate, which is located on the bottom of the gun. To determine the configuration of a gun, obtain its configuration code and refer to Figure 3 and Table 4. 2003 Nordson Corporation
World Gun Series 17 H200 6 STD W T RB CA 0 3 SA A X Code Position 1 Code Position 2 Code Position 3 Code Position 4 Code Position 5 Code Position 6 Code Position 7 Code Position 8 Code Position 9 Code Position 10 Code Position 11 Code Position 12 4209003A Figure 3 Gun configuration code positions (refer to Table 4) Table 4 Explanation of Gun Configuration Code Positions (see Figure 3) Code Position Description Code Values 1 Gun model H200 H400 H440 SURA (SureBead A) 2 Number of modules 2 27 3 Module type STD = standard RAM = right-angle (H200 only) ZC = zero cavity (H200 only) RC = reduced cavity 4 Module position W = wide N = narrow 5 Cordset type T = standard RTD W = water-wash RTD B = bulk melter RTD 6 Cordset position BB = back/back LS = left side RS = right side LB = left back RB = right back 7 Air supply configuration CA = common air IA = independent air PA = programmed air 8 Hose connector angle 0 = no angle 45 = 45 angle 90 = 90 angle 9 Additional hose connectors (all guns have three preinstalled hose connectors) 10 Solenoid valve type SA = H200/H400, <60 mm SB = H200/H400, >60 mm SF = H440, SureBead A XX = no solenoid valve 11 Voltage A = 230 VAC B = 200 VAC 12 Filter X = no filter 3 = one hose connector on each end and one centered on back 5 = one hose connector on each end and three on back (one in the center and one at each end) 2003 Nordson Corporation
18 World Gun Series 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: The following items must be ordered separately: extension cables, if needed (such as when a gun has two cordsets and only one hose will be used) solenoid valves for guns that are not configured with solenoid valves nozzles, if applicable Refer to Parts at the end of this manual for some extension cable part numbers. Refer to the Nordson Adhesive and Sealants Equipment Guide or contact your Nordson representative for solenoid valve and nozzle part numbers. Installation Guidelines Mounting Mount the gun such that the nozzle will be no more than 12 mm, 13 mm, or 0.5 in. from the substrate. 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. 2003 Nordson Corporation
World Gun Series 19 Hydraulic and Pneumatic Connections Use only one fitting to connect a hose to a hose connector on the gun. Insulate the hose-to-gun joint. Insulation cuffs may be ordered separately. Refer to Parts. If the gun was not configured with solenoid valves, use a pipe nipple that has a minimum 6 mm ( 1 / 4 in.) internal diameter and that is no more than 76 mm (3 in.) in length to connect solenoid valves to the gun. Use only clean, dry, non-lubricated air. Ensure that the plant air supply and regulator provide a minimum of 3.4 bar (50 psig) to the gun solenoid valve. Solenoid Valves Ensure that third-party solenoid valves, if used, are capable of being manually triggered at the gun. Use Nordson solenoid valves for optimum gun performance. 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 or rod module(s) solenoid valve(s) Guns ordered with optional features may be shipped with additional components. NOTE: If the gun was ordered without solenoid valves, a pipe nipple assembly will be installed in the gun manifold. NOTE: The solenoid valves on H-440 guns cannot be used on any other type of gun. 2003 Nordson Corporation
20 World Gun Series 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 Equipment and production line configuration may dictate 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 4. Slide the gun mounting clamps onto a 12-mm, 13-mm, or 1 / 2 -in. mounting bar, or disassemble the clamps and reassemble them (with the gun and insulators) onto the mounting bar. Ensure that the insulators are placed between the manifold and the clamps. 2. Securely tighten the mounting clamps. 3. Go to Making the Solenoid Valve Connections. 2 1 3 4209004A Figure 4 Mounting a gun using the mounting clamp (H-402 gun shown) 1. Mounting bar 2. Mounting clamp 3. Insulator 2003 Nordson Corporation
World Gun Series 21 Replace a Gun on an Existing System NOTE: H-440 and SureBead guns are preassembled with a performance-matched solenoid valve. If an H-440 or SureBead gun requires replacement, Nordson Corporation recommends replacing the entire gun assembly (both the gun and solenoid valve) as a single unit. 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. (All guns except H-440 and SureBead) Disconnect the pipe nipple and solenoid valve from the old gun and install them on the new gun. 5. 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. 6. Go to Making the Solenoid Valve Connections. 2003 Nordson Corporation
22 World Gun Series Making the Solenoid Valve Connections Solenoid valves must be connected to an air supply and to a triggering device, such as a pattern controller or timer. If solenoid valves were not specified when the gun was ordered, they must be customer-installed. Install Solenoid Valves (If Applicable) CAUTION: Risk of solenoid valve failure. Solenoid valves must be rated for the output voltage of the triggering device (pattern controller, timer, PLC, etc.) and for use in high-temperature applications. Refer to Installation Guidelines. 2 3 1 1. Port the solenoid valve. Refer to the instructions provided with the solenoid valve or contact your Nordson representative for assistance as needed. 2. See Figure 5. Loosen the locking nut on the top of the pipe nipple assembly installed in the gun manifold and remove the short nipple from the assembly. 3. Install the short nipple in the solenoid valve. 4. Secure the short nipple and solenoid valve assembly to the long pipe nipple by tightening the locking nut around the short nipple. 4209005A Figure 5 Installing a solenoid valve 1. Solenoid valve 2. Short nipple 3. Locking nut Connect the Air Supply Connect a clean, dry, non-lubricated air supply to the solenoid valves. Refer to Installation Guidelines provided earlier in this section and, if applicable, to the instructions supplied with the valve. 2003 Nordson Corporation
World Gun Series 23 Connect the Triggering Device 1. See Figure 6. Remove the solenoid valve terminal block. Save the gasket that is positioned between the terminal block and the valve. 1 2 4209006A Figure 6 Removing the solenoid valve terminal block 1. Terminal block 2. Gasket CAUTION: Do not attempt to pry the terminal block out of the housing. Doing so can damage the electrical connection pins. 2. See Figure 7. Gently press against the edge of one of the terminal block retaining prongs to remove the terminal block from the housing. 4209007A Figure 7 Removing the terminal block from the housing 2003 Nordson Corporation
24 World Gun Series Connect the Triggering Device (contd) CAUTION: Solenoid valves must be rated for the output voltage of the triggering device. Make sure the ratings match. 2 1 24V Solenoid valve terminal block positions 4109008A 3. Thread a 0.75 0.34 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 terminal block. 4. Snap the terminal block back into its housing. 5. Align the gasket on the terminal block housing, plug the terminal block 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. Connecting the Hose NOTE: Refer to the user s guide shipped with the hose for detailed hose installation guidelines. 1. Do one of the following: If an in-line filter is to be used, remove the hose connector preinstalled on the gun and then install the in-line filter. Refer to the instruction sheet provided with the in-line filter. If no in-line filter is used, check the tightness of the preinstalled hose connector. 2. See Figure 8. Connect the hose swivel fitting to the gun hose connector. Use two wrenches to tighten the hose fitting. 3. Connect the gun cordset to the hose. 4. Connect the hose to the melter. Refer to the hose user s guide and/or the melter product manual as needed. 5. Go to Flushing the Gun. 4109009A Figure 8 Connecting the hose (H-440 gun with no in-line filter shown) 2003 Nordson Corporation
World Gun Series 25 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. WARNING: Risk of personal injury or equipment damage. Do not remove the nozzle from SureBead A guns until it is time to start the system and flush the guns. The sharp needle on these guns is exposed whenever the nozzle is removed. 1. Disconnect or turn off the solenoid valve triggering device. 4293102A 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 catch pan under the guns. 4. Flush the guns as appropriate for the type of gun: For all guns except H-200 zero and reduced cavity guns a. Ensure that all nozzles are removed. b. Dispense hot melt from the gun by manually triggering the solenoid valve(s). c. Stop dispensing when the flow of hot melt is clear and free of foreign material. 2003 Nordson Corporation
26 World Gun Series For H-200 zero and reduced cavity guns a. Relieve system hydraulic pressure and disable the gun. Refer to Safety. b. Remove the gun module by removing the two mounting screws from the front of the module. c. Re-pressurize the system; then place the gun into operation. d. Dispense hot melt from the port(s) in the manifold, increasing the pump output in small increments. e. Stop dispensing when the hot melt is clear and free of foreign material. 5. Check for leaks between the gun, hose, and melter. 6. Do one of the following: Continue to the next procedure, Installing Nozzles, to install nozzles. Reinstall the gun module(s). Tighten the module mounting screws to 3.3 Nm (30 in.-lb). Installing Nozzles WARNING: Risk of personal injury or equipment damage. The sharp needle on SureBead guns is exposed whenever the nozzle is removed. NOTE: This procedure does not apply to H-200 right-angle, zero cavity, or reduced cavity guns. 4293102A See Figure 9. Install nozzles by threading the nozzle onto the gun by hand and then using a torque wrench to tighten the nozzle to no more than 4.5 Nm (40 in.-lb). 4293007A Figure 9 Installing a nozzle 2003 Nordson Corporation
World Gun Series 27 Operation The gun is now ready for routine operation. Refer to the melter product manual for operating instructions. WARNING: H-400 gun modules are adjustable. Adjusting the gun modules for low air pressure operation without making a corresponding reduction in system hydraulic pressure may cause the gun modules to remain open. Refer to Gun Module Adjustments to properly adjust the operating air pressure for H-400 modules if the guns must be operated at a low air pressure. WARNING: H-440 and SureBead 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. Gun Module Adjustments The modules on H-200 zero cavity and H-400 guns can be adjusted. For most applications, however, no adjustments should be needed. Nordson Corporation recommends that modules be adjusted only if absolutely necessary to achieve the desired application performance. Adjusting H-200 Zero Cavity Modules H-200 zero cavity guns are equipped with a micro-adjuster that allows the nozzle flow rate to be decreased approximately 30 percent from the maximum flow rate set at the factory. WARNING: System pressurized! Relieve system pressure before attempting to adjust the gun. If the micro-adjuster is unscrewed too far, hot melt can be released under pressure. Failure to relieve system pressure can result in personal injury. 1. Relieve system hydraulic pressure and disable the gun. Refer to Safety. See Figure 10. 2. Loosen the locking nut. 2003 Nordson Corporation
28 World Gun Series Adjusting H-200 Zero Cavity Modules (contd) 3. Hold the loading screw in place and turn the flow-rate adjusting nut as follows: To decrease the flow rate, turn the flow-rate adjusting nut clockwise. To increase the flow rate, turn the flow-rate adjusting nut counterclockwise. NOTE: Each quarter-turn of the adjusting nut (clockwise) reduces the stroke of the module by 0.0254 mm (0.001 in.). 4. Tighten the locking nut. 5. Check the flow rate. Repeat this procedure as needed until the desired flow rate is achieved. 1 2 3 Figure 10 Micro-adjuster on an H-200 zero cavity module 1. Loading screw 3. Flow-rate adjusting nut 2. Locking nut 4201100B 2003 Nordson Corporation
World Gun Series 29 Adjusting H-400 Modules The normal operating air pressure range for H-400 guns is 3.4 5.5 bar (50 80 psi). The normal operating hydraulic pressure range is 30 90 bar (450 1,300 psi). 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. Use these procedures as needed to adjust H-400 guns for low-pressure operation. 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 5. 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. Table 5 Increasing Gun Air Pressure to Operate at Low Hydraulic Pressure To operate at this hydraulic pressure... The minimum gun air pressure required is... 30 90 bar (450 1,300 psi)* 20 90 bar (300 1,300 psi) 14 90 bar (200 1,300 psi) 3.4 bar (50 psi)* 4.1 bar (60 psi) 4.8 bar (70 psi) *This is the factory setting. 1 Compensating for Low Gun Air Pressure If your application requires that you operate at a gun air pressure below 3.4 bar (50 psi) and at a hydraulic pressure below 30 bar (450 psi), you must reduce the gun module spring tension. 2 NOTE: The needle stroke on H-400 modules cannot be adjusted. Only the module spring tension can be adjusted. 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. 4293024A See Figure 11. To reduce the gun module spring tension, loosen the locking nut and turn the adjustment screw counterclockwise in 1 / 2 -turn increments. Each 1 / 2 turn reduces the hydraulic pressure capability by 7 bar (100 psi). Refer to Table 6. Figure 11 Adjustment screw on an H-400 module 1. Adjustment screw 2. Locking nut 2003 Nordson Corporation
30 World Gun Series Compensating for Low Gun Air Pressure (contd) Table 6 Adjusting an H400 Gun Module to Operate at Low Gun Air Pressure and Low Hydraulic Pressure Adjustment Screw Position Minimum Gun Air Pressure Available Minimum Hydraulic Pressure Factory setting Approximately 1 / 2 turn counterclockwise from factory setting Approximately 1 turn counterclockwise from factory setting 3.4 bar (50 psi) 30 bar (450 psi) 24 bar (350 psi) 17 bar (250 psi) Returning an H400 Gun Module to the Factory Setting 1. Disable the gun. Refer to Safety. 2. See Figure 11. Loosen the module locking nut. 3. Turn the adjustment screw clockwise only until it bottoms out. Do not over-tighten the screw. 4. Turn the adjusting screw counterclockwise two revolutions. The air cap is marked to allow you to precisely reset the screw. 5. Tighten the locking nut while holding the adjustment screw in place. 2003 Nordson Corporation
World Gun Series 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 from a single gun module or from any module on a multi-module gun Adhesive level low No input power 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 Add adhesive. Connect power to the melter and auxiliary devices. Ensure that all disconnect switches or circuit breakers are on. Adjust the setting. Refer to the melter product manual. Verify that the READY light is on and the hot melt is molten. Flush the melter filter. Refer to the melter product manual. 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 Repair. Continued... 2003 Nordson Corporation