Instruction Sheet P/N 237494_02 Converting an FP-200 Extrusion Gun to an FP-200 Swirl Gun WARNING! Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Introduction This conversion kit provides instructions to convert an FP-200 extrusion gun (P/N234897)toanFP-200swirlgun(P/N234896). Itdoesnot accommodate any other FP-200 gun part numbers. The Nordson FP-200 gun, when combined with the appropriate balance-assist devices, allows the operator to maintain a neutral wrist position while manually applying hot melt adhesives and sealants to horizontal substrates. Two versions of the FP-200 gun are available: extrusion and swirl. Extrusion guns can meet a wide variety of bead deposition requirements while swirl guns permit exceptional control of spiral pattern density and size. Nordson offers two conversion kits: One to convert an extrusion gun to a swirlgunandonetoconvertaswirlguntoanextrusiongun. This instruction sheet contains the procedures for converting an extrusion gun to a swirl gun. Using this Instruction Sheet This instruction sheet contains the following procedures: PreparingtoConvertanFP-200Gun. Completethisprocedure before performing the conversion. ConvertinganFP-200ExtrusionGuntoaSwirlGun RestoringtheSystemtoNormalOperation Usethepartslistsattheendofthisinstructionsheettoorderanynecessary Nordson parts, such as swirl nozzles or the FP-200 swirl gun heat shield.
2 Converting an FP-200 Extrusion Gun to an FP-200 Swirl Gun Preparing to Convert an FP-200 Gun WARNING! Hot! Risk of burns! Hot applicator parts, splashed hot melt material, and hot gun surfaces can cause severe burns. Wear long-sleeved, heat-protective clothing, safety goggles, and heat-protective gloves. Hot melt material may be released forcefully. WARNING: Risk of burns. System or material pressurized. Air trapped in hosesandgunscanspitoutmoltenadhesivethatcancausesevereburns. Failure to relieve hydraulic pressure can result in serious burns. Relieve hydraulic pressure when instructed to do so. WARNING! Even when switched off, Nordson applicators, hoses, and guns contain electrical potentials that can cause death. Disconnect and lock out line voltage to the applicator when instructed to do so. 1. Relieve hydraulic pressure(refer to the Relieving Hydraulic Pressure procedure in the FP-200 gun product manual). 2. Switch the applicator circuit breaker to the OFF position. 3. Disconnect and lock out electrical power to the applicator. 4. Shutofftheairsupplytothegun. 5. Removetheheatshieldfromtheexistinggunasfollows: a. Remove the auxiliary guide handle. b. Disconnect the extrusion air line from the service block. c. Remove the heat shield. d. Reconnect the extrusion air line. Do not reinstall the auxiliary guide handle. 6. Remove the existing gun from the suspension system by disconnecting the hose hydraulically and electrically and by disconnecting the air line. Part237494_02
Converting an FP-200 Extrusion Gun to an FP-200 Swirl Gun 3 Converting an FP-200 Extrusion Gun to a Swirl Gun CAUTION!Thekitforconvertinganextrusionguntoaswirlgundoesnot include a heat shield. To comply with Underwriter's Laboratory(UL), Canadian(C-UL), and Conformité Européenne(CE) standards, heat shield P/N 234965mustbeusedontheconvertedswirlgun. Theextrusiongun heatshieldis19mm( 3 / 4 in.)shorterthantheswirlgunheatshieldandthus cannotsufficientlycoveraswirlgunasrequiredtomeetul,c-ul,andce safety requirements. FollowthisproceduretoconvertanFP-200extrusionguntoaswirlgun. Figures 1 and 2 identify the components referred to in the procedure (for clarity, the heat shield is not shown). See Figure 1.
4 Converting an FP-200 Extrusion Gun to an FP-200 Swirl Gun Converting an FP-200 Extrusion Gun to a Swirl Gun (contd) 1 5 3 10 4 1 2 3 4 5 9 6 7 Figure 1 FP-200 Extrusion Gun Components 1. Gun mounting plate 2. Mounting bracket 3. Extrusion air line universal elbow 4. Outlet air line swivel fitting 5. Outletairline 6. Extrusion air line 8 7. Extrusion air line male connector andtubenut 8. Module 9. Service block 10. Bulkhead fitting Part237494_02
Converting an FP-200 Extrusion Gun to an FP-200 Swirl Gun 5 Figure 1 FP-200 Swirl Gun Components 1. Multi-plane swivel fitting (hydraulic hose connection) 2. High-temperature air line tube 3. Gun mounting plate 4. Air regulator 5. Urethane air line tube 6. Trigger safety 7. Trigger 8. Trigger handle 9. Extrusion air line 10. Module(CF-200 Wide Pattern) 11. Air manifold 12. Swirlairline 13. Service block(gun body) 14. Cordset connection 15. Mounting bracket
6 Converting an FP-200 Extrusion Gun to an FP-200 Swirl Gun Disassembling the Extrusion Gun Make sure you have completed the Preparing to Convert an FP-200 Gun procedure before proceeding. See Figure 3 for the following procedure. 1. Unthreadandremovetheoutletairlineswivelfittingfromtheoutletair line universal elbow. 2. Disconnect the mounting bracket from the gun mounting plate. 3. Disconnect the outlet air line universal elbow from the bulkhead fitting andsetitaside. Itwillbeusedlater. 4. Disconnect the bulkhead fitting and mounting bracket from the extrusion air line universal elbow. 5. Extract the bulkhead fitting from the mounting bracket. 2 1 3 4 6 Figure 2 Disconnecting the Extrusion Air Line(Top View) 1. Gun mounting plate 2. Outlet air line universal elbow 3. Outlet air line swivel fitting 5 4. Bulkhead fitting(including washers and locking nut) 5. Extrusion air line universal elbow 6. Mounting bracket Part237494_02
Converting an FP-200 Extrusion Gun to an FP-200 Swirl Gun 7 Assembling the Extrusion Gun SeeFigure4forsteps1through5. 1. Reinstall the mounting bracket on the opposite side of the gun mounting plate. Ensure that the mounting bracket is positioned as shown in Figure 4. 2. Install the air regulator in the mounting bracket by removing one locking nut and washer, inserting the regulator through the hole in the mounting bracket, then replacing and tightening the locking nut and washer. EnsurethattheTmanifoldinletisfacingawayfromthegunmounting plate. NOTE: For best results, lightly coat the connector threads of the universal elbows, T manifold, outlet air line swivel fitting, and#10 32 connector with an anaerobic sealant before assembling them as directed insteps3through5andstep8. CAUTION! Do not overtighten fittings when performing the following steps. Overtightening can cause the connectors to crack and snap off. Finger-tightening, combined with the use of a sealant, is usually sufficient. CAUTION! Only a small amount of sealant is required. Do not overcoat connectors with sealant. Overcoating can cause excess sealant to migrate into the air passages. 3. Attach the extrusion air line universal elbow to the T manifold. 4. ThreadtheTmanifoldintotheairregulator,thenthreadtheoutletairline swivel fitting into the T manifold. Carefully tighten the fittings.
8 Converting an FP-200 Extrusion Gun to an FP-200 Swirl Gun Assembling the Extrusion Gun (contd) 5. Connecttheuniversalelbowthatwasremovedinstep4of Disassembling the Extrusion Gun to the air regulator. 1 52 3 4 5 4 6 4 4 8 7 Figure 3 Installing the Air Regulator(Top View) 1. Mounting bracket 2. Air regulator, washers, and locking nuts 3. T manifold inlet 4. Sealant 5. T manifold 6. Outlet air line swivel fitting 7. Extrusion air line universal elbow 8. Swirl air line universal elbow Part237494_02
Converting an FP-200 Extrusion Gun to an FP-200 Swirl Gun 9 6. Install the air manifold on the service block using the two socket-head screws. 1 2 Figure 4 1. Service block 2. Air manifold Installing the Air Regulator(Top View) 3 3. Socket-head screws SeeFigure5forsteps7through9. 7. Threadtheswirlairlinemaleconnectorintotheairmanifold. 8. Thread the#10 32 connector into the swirl air line universal elbow and carefully tighten it.
10 Converting an FP-200 Extrusion Gun to an FP-200 Swirl Gun Assembling the Extrusion Gun (contd) 9. Assembletheswirlairlineasfollows: a. Slidetheblackplastictubeclampontotheplastictube. b. Insertthecurvedendofthemetaltubeintothemaleconnectorand tighten the tube nut. c. Inserttheotherendofthemetaltubeintotheplastictube. d. Slidethetubeclamptowithin6mm(0.25in.)oftheendoftheplastic tube and squeeze it shut with pliers. 1 2 3 4 6mm(0.25in.) 5 6 7 8 9 Figure 5 Assembling the Swirl Air Line 1. Swirl air line universal elbow 2. Sealant 3. #10 32 connector 4. Plastic tube 5. Tube clamp 6. Metal tube 7. Service block(partially shown) 8. Male connector tube nut 9. Air manifold Part237494_02
Converting an FP-200 Extrusion Gun to an FP-200 Swirl Gun 11 10. Install the new CF-200 wide pattern module on the service block as follows: a. Remove the old module. b. Lubricate the new module's o-rings. c. Wipe off any hot melt material on the service block, especially around the air passages. d. Apply anti-seize lubricant to the two module socket-head screws. CAUTION: Do not overtighten. Overtightening can strip the threads. Figure 6 Installing the New Module e. Use the socket head screws to secure the new module to the service block. Torque the screws to 30 in-lb. NOTE: For best results, torque the screws again after the applicator reaches operating temperature. NOTE: Nozzles must be ordered separately. Refer to Parts. 11. Install the swirl gun heat shield as follows: a. Disconnect the swirl and extrusion air lines by unthreading the tube nuts at the male connectors on the service block and air manifold. b. Wrapthecoveraroundthemoduleandserviceblockandfastenit. c. Reconnect the swirl and extrusion air lines. 12. Reinstall the auxiliary guide handle. 13. Go to Restoring the System to Normal Operation. E 2012 Nordson Corporation
12 Converting an FP-200 Extrusion Gun to an FP-200 Swirl Gun Restoring the System to Normal Operation Use this procedure to restore the applicator and converted gun to normal operation. 1. Reconnect the gun to the suspension system by reconnecting the gun and hose hydraulically and electrically, then reconnecting the gun to the air supply. 2. Restore electrical power to the applicator. 3. Move the applicator circuit breaker to the ON position. 4. Let the unit and hose reach operating temperature. 5. Retighten gun-to-hose and gun-to-applicator fittings. 6. Check for low pressure leaks at the gun-to-hose fitting. 7. Turntheairsupplyon. 8. Whileslowlyrestoringairpressuretothegunto379.2kPa(55psi),check for leaks. Retighten fittings as necessary. 9. Resume normal operation. Parts To order parts, call the Nordson Customer Service Center at 800-241-8777 or contact your local Nordson representative. Use the following parts lists to describe and locate parts correctly. Part237494_02
ConvertinganFP-200ExtrusionGuntoanFP-200SwirlGun 13 Conversion Kit and Accessories Table1liststheFP-200conversionkitpartnumber(P/N)andthepart numbersforthepartscontainedinthekit. Italsoliststhepartnumbersfor the extrusion gun heat shield and for Loctite, which is an anaerobic sealant. Table 1 FP-200 Gun Conversion Kit and Accessories Part Description Quantity Note 303 028 Kit, Extrusion to Swirl, FP-200 Gun A, B 234894 Fitting,#10 32,T,Manifold 1 220643 Connector,Male,1/8in.x1/8in. 1 981056 Screw,Socket#8 32x0.750in. 2 983011 Washer,Lock,Internal,#8 2 234964 Manifold,Air,FP-200 1 234880 Tube,Manifold,FP-200 1 101887 Clamp,Tube0.228in. 1 234969 Tube,ManifoldAssembly 1 234882 Regulator,Air,Miniature 1 157266 Module,CF-200,WidePattern 1 234 965 Shield, Heat, FP-200, Swirl 1 174 885 Loctite 222, low strength, 0.5 ml NOTE A: ThiskitconvertsP/N234897toP/N234896. Ordertheheatshield(P/N234965)separately. B: Order nozzles separately. Refer to Table 2.
14 Converting an FP-200 Extrusion Gun to an FP-200 Swirl Gun Nozzles The FP-200 swirl gun accommodates a variety of swirl nozzles. Table 2 lists the part numbers for nozzles commonly used with the FP-200 swirl gun. Table 2 Nozzles Commonly Used with the FP-200 Swirl Gun Nozzle Type P/N Orifice Diameter Notes Wide pattern swirl nozzles 125 607 131 998 0.64 mm (0.025 in.) 0.76 mm (0.030 in.) One-piece nozzle and nut assembly Use with CF-200 wide 131 635 1.17 mm (0.046 in.) pattern module (P/N 157 266) Swirl nozzles 104 100 0.20 mm (0.008 in.) Use with CS-WF 104 101 0.25 mm (0.010 in.) nozzle retaining nut (P/N 119 202) 860 548 0.31 mm (0.012 in.) Use with CF-200 wide 860 574 0.36 mm (0.014 in.) pattern module (P/N 157 266) 860 575 0.41 mm (0.016 in.) 860 226 0.46 mm (0.018 in.) 860 435 0.51 mm (0.020 in.) 100 728 0.64 mm (0.025 in.) 810 381 0.76 mm (0.030 in.) 810 382 1.02 mm (0.040 in.) 810 300 1.27 mm (0.050 in.) Issued 10/12 Original copyright date 1997. Nordson and the Nordson logo are registered trademarks of Nordson Corporation. Loctite is a registered trademark of Loctite Corporation. E 2012 Nordson Corporation