eries H-200 Guns Customer Product Manual Issued 8/05 NORDON CORPORATION DULUTH, GEORGIA UA 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 ervice 11475 Lakefield Drive Duluth, GA 30097 Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2001. 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, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, Cleanleeve, Cleanpray, ColorMax, Control Coat, Coolwave, Cross Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Durasystem, Easy Coat, Easymove Plus, Econo-Coat,EFD,ETI,Excel 2000,Fillmaster,FlexiCoat,Flexi-pray,Flex-O-Coat,Flow entry,fluidmove,foammelt,foammix,heli-flow,helix,horizon, Hot hot,icontrol,isocoil,isocore,iso-flo,jr,kb30,kinetix,little quirt,magnastatic,march,meg,meltex,microcoat,micromark,microet,millennium, Mini quirt, Moist-Cure, Mountaingate, Multican, Nordson, Omnican, OptiMix, Package of Values, PatternView, PermaFlo, Plasmod, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, ProBlue, Pro-Flo, ProLink, Pro-Meter, Pro-tream, RBX, Rhino, aturn, C5,. design stylized, eal entry, elect Charge, elect Coat, elect Cure, lautterback, mart-coat, older Plus, pectrum, peed-coat, praymelt, pray quirt, uper quirt, urebead, ure Coat, ure-max, Tela-Therm, Tracking Plus, Trends, Tribomatic, Ultrasaver, Unican, UpTime, Veritec, VersaBlue, Versa-Coat, Versa-creen, Versa-pray, Walcom, Watermark, and When you expect more. are registered trademarks of Nordson Corporation. Accubar, Advanced Plasma ystems, AeroDeck, AeroWash, Apogee, AquaCure, AT, Auto-Flo, Autocan, BetterBook, Celero, Chameleon, Check Mate, Controlled Fiberization, Control Weave, CPX, DispensLink, Dry Cure, DuraCoat, DuraPail, Dura-creen, Easy Clean, Eclipse, EcoDry, e.dot, E-Nordson, Equi=Bead, EP, e tylized, Exchange Plus, Fill entry, Gluie, HDLV, iflow, ion, Iso-Flex, itrend, itrax, KVLP, Lacquer Cure, Lean Cell, Maxima, MicroFin, MicroMax, Minimeter, Multifil, Optitroke, Origin, PatternPro, PCI, PluraMix, Powder Pilot, Powercure, Primarc, Printplus, Process entry, Pulse pray, PurTech, QuadCure, Ready Coat, Royal Blue, coreguard, elect eries, ensomatic, haftshield, heetaire, pectral, pectronic, peedking, pray Works, ummit, ure Brand, ure Clean, urewrap, wirl Coat, Tempus, ThruWave, Trade Plus, Trak, TrueBlue, Ultra, Ultrasmart, Universal, Vantage, Viper, 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
Table of Contents i Table of Contents afety... 1 afety Alert ymbols... 1 Responsibilities of the Equipment Owner... 2 afety Information... 2 Instructions, Requirements, and tandards... 2 User Qualifications... 3 Applicable Industry afety Practices... 3 Intended Use of the Equipment... 3 Instructions and afety Messages... 3 Installation Practices... 4 Operating Practices... 4 Maintenance and Repair Practices... 5 Equipment afety Information... 5 Equipment hutdown... 5 General afety Warnings and Cautions... 6 Other afety Precautions... 9 First Aid... 10 afety Labels and Tags... 10 Description... 12 Intended Use... 13 Hot Melt Materials... 13 Auxiliary Devices and pare Parts... 13 Dimensions... 13 Installation... 14 Installation Guidelines... 15 Mounting... 15 Connections... 15 olenoid Valves... 15 Unpacking and Inspection... 16 Mounting the Gun... 16 Mount the Gun on a New or Existing ystem... 16 Replace the Gun on an Existing ystem... 17 Mount a Low-Profile Gun... 18 Connecting the olenoid... 18 Connecting the Gun and Hose... 19 Flushing the Gun... 20 Adjusting Zero-Cavity Modules... 21 Troubleshooting... 22 Troubleshooting Table... 22 Diagnostic Procedures... 24 DP1. Check the olenoid Valve... 25 DP2. Check for a Clogged Nozzle or Module... 25 DP3. Check Module Operation... 26 DP4. Check the Heater... 26 DP5. Check the RTD... 27
ii Table of Contents Maintenance... 29 Nozzle Cleaning... 29 Integral Filter Cleaning... 30 Inspecting the Gun Wiring... 33 Repair... 33 Replacing the RTD or Heater... 33 Accessing the RTD or Heater... 34 Replacing the RTD or Heater... 34 Restoring the ystem to Normal Operation... 35 Replacing the Module... 36 Replacing the Manifold Body... 36 Replacing the olenoid Valve... 36 Parts... 37 Accessories and ervice Parts... 37 Cordsets and RTDs... 37 eal Rebuilding Kits... 37 Filters... 38 Manifold Bodies, Heaters, and Integral Filters... 40 Gun Replacement Modules... 41 olenoid Valves... 42 pecifications... 43
eries H-200 Guns 1 eries H-200 Guns afety 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. afety Alert ymbols 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.
2 eries H-200 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. afety 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 tandards 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.
eries H-200 Guns 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 afety 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 afety 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 afety 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.
4 eries H-200 Guns 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 afety Data heet (MD) 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 afety Information or the material manufacturer s instructions and MD for PPE requirements. Do not use equipment that is malfunctioning or shows signs of a potential malfunction.
eries H-200 Guns 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 MD supplied with equipment cleaning compounds. NOTE: MDs 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 MD or contact the authority having jurisdiction for information. Keep equipment safety warning labels clean. Replace worn or damaged labels. Equipment afety 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 hutdown 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 ystem 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.
6 eries H-200 Guns De-energizing the ystem 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 afety 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)
eries H-200 Guns 7 Equipment Type HM Table 1 General afety 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 MD. 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 MD 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: ystem 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...
8 eries H-200 Guns General afety Warnings and Cautions (contd) Table 1 General afety Warnings and Cautions (contd) Equipment Type HM, PC 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 MD 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...
eries H-200 Guns 9 Equipment Type HM 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: ome 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 MD supplied with the compound. ome 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 afety 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. uspend dispensing handguns by their proper suspension point.
10 eries H-200 Guns 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. eek expert medical attention immediately. Give the MD for the hot melt to the medical personnel providing treatment. afety 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. 1 3 4 5 6 Figure 1 2 afety Labels and Tags 4201092A
eries H-200 Guns 11 Table 2 Equipment afety Labels and Tags Item Part Description 1. 273635 CAUTION: 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. 2. 182036 WARNING: ystem pressurized! Relieve system pressure before disconnecting the hose from the gun. Failure to relieve system pressure before disconnecting the hose may cause personal injury. 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. 600137 WARNING: Disconnect power and remove system pressure before disassembly or maintenance. Failure to follow these instructions may result in serious personal injury. 4. 243352 WARNING: Fire, injury, or equipment damage can result if cleanout materials do not meet the following requirements: 1. Minimum flashpoint to be 288 _C (550 _F). 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. 600103 WARNING: 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. 243352 WARNING: 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.
12 eries H-200 Guns Description This manual provides information about eries H-200 RTD controlled modular hot melt guns in filtered and unfiltered configurations. Table 3 presents the gun configurations and module designs supported in this document. Figure 2 illustrates a typical H-200 gun assembly. Gun Configuration Table 3 upported Gun Configurations and Modules Module tandard Minimum Reduced Zero Cavity Zero Cavity Cavity Cavity Case ealing Right Angle tandard n n n n n Low profile n n n n n Mini-bead lot Nozzle AquaGuard n n n n n 1 2 3 4 5 9 6 7 8 4201052A Figure 2 Typical H-200 Gun Assembly (Unfiltered Gun hown 1. olenoid valve 6. Cordset 2. Pipe nipple 7. Manifold body 3. Mounting clamp 8. Hose connector or inline filter 4. Mounting bar 9. Module (standard shown) 5. Insulator
eries H-200 Guns 13 Intended Use Nordson H-200 guns are specifically designed for industrial applications that require the deposition of a precisely controlled stream of hot melt material onto a moving substrate. H-200 guns are designed to be rigidly mounted, pneumatically operated, and triggered by an electrically controlled solenoid valve. eries H-200 guns are designed for use only with Nordson melters and hoses. Hot Melt Materials Nordson H-200 guns are designed to process packaging grade adhesives. Do not process polyurethane reactive or polyamide hot melt materials through the H-200 guns. Auxiliary Devices and pare Parts H-200 guns should only be connected to approved auxiliary devices. Use only new Nordson replacement parts or approved factory refurbished parts. Dimensions 40 mm (1.59 in.) 22 mm (0.875 in.) 114 mm (4.52 in.) 96 mm (3.86 in.) 12 mm (0.50 in.) 25 mm (1.0 in.) 40 mm (1.59 in.) 42 mm (1.66 in.) Figure 3 H-200 Unfiltered Gun Dimensions
14 eries H-200 Guns Dimensions (contd) Clearance required for removal of filter 94 mm (3.70 in.) 24 mm (0.96 in.) 129 mm (5.10 in.) 133 mm (5.25 in.) Figure 4 109 mm (4.30 in.) 102 mm (4.05 in.) H-200 Integral Filter Gun Dimensions 4201073 Installation H-200 guns are installed using a six-step process: 1. unpack and inspect 2. mount 3. connect the air supply 4. connect the gun to the hose 5. flush 6. install nozzles Guns ordered with special options may require additional installation steps that are not described here.
eries H-200 Guns 15 Installation Guidelines Use the following installation guidelines to achieve optimum gun performance. Mounting Mount the gun so that the nozzle is no more than 13 mm (0.5 in.) from the substrate. Install integral filter guns with a minimum 94 mm (3.70 in.) clearance above the gun manifold, so that the filter assembly can be removed. Install integral and aturn filter guns with sufficient clearance at the rear of the gun to allow operation of the manifold drain valve. Install the gun with sufficient clearance to the rear or sides of the gun to allow for removal of the manifold body cover or endplates. 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. Connections Only use one fitting to connect the hose to the gun. Insulate the fitting between the hose and gun. Keep the pipe nipple connecting the solenoid valve to the gun to less than 76 mm (3 in.) in length. olenoid Valves Only use solenoid valves rated above 0.5 Cv and with a service temperature above 85 _C (185 _F). Third-party solenoid valves must be capable of being manually triggered at the gun. Use Nordson solenoid valves for optimum performance. Only use clean, dry, and non-lubricated air. Ensure that the plant air supply and regulator provide a minimum of 340 kpa (50 psig) to the gun solenoid valve.
16 eries H-200 Guns Unpacking and Inspection 1. Unpack the gun using normal care. 2. Inventory and inspect the gun. H-200 guns are shipped with the following components. Module(s) assembled to the manifold body Integral mounting clamp Installation kit NOTE: Guns ordered with optional features may be shipped with additional components. The following additional components may also be required: Approved solenoid valve (see Installation Guidelines) olenoid valve installation kit (for Nordson solenoid valves) Mounting the Gun This section describes three gun-mounting options: mount the gun on a new or existing system replace the gun on an existing system mount a low-profile gun The configuration of your equipment and production line may require a variation in the mounting options described in this section. Regardless of the option used, observe the information provided in Installation Guidelines. Mount the Gun on a New or Existing ystem 1. Attach the gun assembly to the parent machine using the clamp or threaded mounting rod (low-profile gun) provided. 2. ee Figures 5 and 6. lide the mounting clamp onto a mounting bar or disassemble the clamp and reassemble it (with the gun and insulator) onto a mounting bar. Ensure that the insulator is placed between the manifold body and the clamp. 4201093A Figure 5 Using a Mounting Bar
eries H-200 Guns 17 3. ecurely tighten the mounting clamp. 4. Go to Connecting the olenoid Valve. 1 2 4201070 Figure 6 Disassembling the Clamp 1. Mounting clamp 2. Insulator Replace the Gun on an Existing ystem 1. Relieve system hydraulic pressure and disable the gun. Refer to afety. 2. ee Figure 7. Disconnect the pipe nipple and solenoid from the gun. 3. Disconnect the hose from the gun, electrically and hydraulically. 4. eparate the existing gun from its mounting. If the mounting clamp will not be reused, remove it from the mounting bar. 5. Mount the new gun and insulator onto the existing mounting clamp or disassemble the new gun s mounting clamp, then reassemble the clamp (with gun and insulator) onto the existing mounting bar. Tighten the clamp securely. 6. Go to Connecting the olenoid Valve. 4201094A Figure 7 Removing and Existing Gun
18 eries H-200 Guns Mount a Low-Profile Gun ee Figure 8. Mount a low-profile gun to the parent machine using the threaded mounting rod. Figure 8 Typical Low-Profile Gun 4201083A Connecting the olenoid CAUTION: Risk of solenoid valve failure. olenoid valves must be rated for the output voltage of the triggering device (pattern control, timer, PLC, etc.) and for use in high-temperature applications. Refer to Installation Guidlines. 1. Port the solenoid valve. Refer to the instruction sheet provided with the solenoid valve. 2. Connect the solenoid valve to the gun, using the pipe nipple provided in the installation kit. Nordson recommends the use of a quick-disconnect fitting (P/N 231262) between the solenoid valve and gun. Individually ported guns may require special solenoid valve configurations. Contact your Nordson representative for assistance. 3. Connect the solenoid valve to a regulated, dry, and non-lubricated air supply. Refer to the instruction sheet supplied with the valve and the Installation Guidelines provided earlier in this section. 4. Connect the solenoid valve to the triggering device. Refer to the instructions provided with both the triggering device and solenoid valve. 5. Go to Connecting the Gun and Hose.
eries H-200 Guns 19 Connecting the Gun and Hose NOTE: Refer to the user s guide shipped with each hose for detailed hose installation guidelines. 1. Do one of the following: If an in-line filter is to be used (see Parts), remove the hot melt hose adapter fitting supplied with the gun, then install the filter assembly. Refer to the instruction sheet provided with the in-line filter assembly. If no in-line filter is required, check the tightness of the adapter fitting on the gun. 2. ee Figure 9. Connect the hose swivel fitting to the adapter fitting on the gun. Use two wrenches to tighten the hose fitting. 3. Connect the gun cordset or wiring to the hose. 4201075 Figure 9 Connecting the Hose and Gun (no In-line Filter) 4. ee Figure 10. Insulate the gun-to-hose fittings or filter using the cuff provided in the installation kit. Figure 10 Insulating the Gun-to-hose Fittings or Filter 4201102A 5. Connect the hose to the melter. Refer to the user s guide provided with the hose. 6. Go to Flushing the Gun.
20 eries H-200 Guns Flushing the Gun Before placing the gun into operation, it must be flushed of foreign material. Procedures for flushing both standard guns and reduced- or zero-cavity guns are provided in this part. CAUTION: Risk of equipment damage. 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 triggering device. 2. Remove aturn, right-angle, or multi-orifice nozzles. 3. Turn the melter on, then bring the system up 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. 4. Place a catch pan under the gun. 5. Do one of the following: For standard guns: a. Dispense hot melt from the gun by manually triggering the solenoid valve(s). b. top dispensing when the flow of hot melt is clear and free of foreign material. For reduced- or zero-cavity guns: a. Relieve system hydraulic pressure and disable the gun. Refer to afety. b. Remove the module from the manifold body by unscrewing the two socket-head 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 body by manually triggering the gun solenoid valve. If necessary, increase the pump output in small increments. e. top dispensing when the hot melt is clear and free of foreign material. 6. Check for leaks between the gun, hose, and melter.
eries H-200 Guns 21 7. Do one of the following: Reinstall the nozzle(s). Tighten the nozzle to no more than 4.5 Nm (30 in.-lb). Reinstall the module(s). Tighten the socket-head screws to 3.3 Nm (30 in.-lb). The system in now ready for routine operation. Refer to the melter product manual for operating instructions. Adjusting Zero-Cavity Modules Zero-cavity guns are equipped with a micro-adjuster that allows the nozzle flow rate to be decreased approximately 30% from the maximum flow rate setatthefactory. 1. Relieve system hydraulic pressure and disable the gun. Refer to afety. 2. ee Figure 11. Loosen the bottom locking nut (1). 3 2 1 4 8.9 mm (0.35 in.) 5 Figure 11 Microadjuster 1. Bottom locking nut 2. Flow rate adjusting nut 3. Load screw 4. Top locking nut 5. DO NOT ADJUT 4201100A 3. Hold the load screw (3) in-place and loosen the top locking nut (4).
22 eries H-200 Guns Adjusting Zero-Cavity Modules (contd) WARNING: ystem 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. 4. Adjust the flow rate. To decrease the flow rate, turn the flow-rate adjusting nut (2) clockwise. To increase the flow rate, turn the flow-rate adjusting nut counter-clockwise. NOTE: Each quarter-turn of the adjusting nut (clockwise) reduces the stroke of the module by.0254 mm (.001 in.). 5. Tighten the top and bottom locking nuts. 6. Check the flow rate. If necessary, repeat steps one through five. Troubleshooting 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 damage to the equipment. Troubleshooting Table The following table lists the problems that are most likely to occur with H-200 guns, the possible causes of each problem, and steps for corrective action. Where applicable, cross-references are made to expanded diagnostic procedures (DP), which are provided later in this section, or to other sections of this manual.
eries H-200 Guns 23 Problem Possible Cause Corrective Action 1. No adhesive flow Adhesive level low Add adhesive. from any module of a multi-module gun or from a single-module gun No input power Connect power to the melter and auxiliary devices. Make sure that all disconnect switches or circuit breakers are on. 2. No adhesive flow from some modules in a multi-module gun 3. Adhesive or air flows from bleed hole Melter, hose, or gun temperature setting is too low ystem is not at operating temperature Insufficient air pressure to the piston pump Adjust. Refer to the melter product manual. Verify that the READY light is on and the hot melt is molten. Verify air pressure by flushing the filter. Refer to the melter product manual. -- or -- -- or -- Melter motor not operating Verify motor operation. Refer to the melter product manual. No air supply to the solenoid valve Check the plant air supply pressure. olenoid valve has failed Check the solenoid valve and replace it if defective. Refer to DP1. Hose is clogged Replace the hose. Nozzle is clogged Check the nozzle. Refer to DP2. Module has failed Check for correct module operation. Refer to DP3. Dirty or faulty triggering device Clean or replace the triggering device. Faulty encoder Test the encoder and replace if defective. Nozzle is clogged Check the nozzle. Refer to DP2. Module has failed Air or adhesive seals have failed. Check the module for correct operation. Refer to DP3. Replace or rebuild the module. Refer to Repair and Parts. Continued...
24 eries H-200 Guns Troubleshooting Table (contd) Problem Possible Cause Corrective Action 4. Modules not Gun loading screw is not properly Contact Nordson technical support. triggering at the same time on multi-module gun set Module has failed Check the module for correct operation. Refer to DP3. 5. Gun fails to heat or underheats No power Gun temperature setting is too low Failed gun heater (open or short) Failed gun RTD (open or short) 6. Gun overheats Melter, hose, or gun temperature setting is too high horted RTD (unit should shut down) hort in the heater control circuit Check that the melter is on. Refer to the melter product manual. Adjust the temperature setting. Refer to the melter product manual. Check for an open heater circuit. Refer to DP4. Check RTD resistance. Refer to DP5. Adjust the setting. Refer to the melter product manual. Check resistance of the RTD. Refer to DP5. Troubleshoot the melter. Refer to the melter product manual. Diagnostic Procedures The following diagnostic procedures (DPs) are referenced in the Troubleshooting Table.
eries H-200 Guns 25 DP1. Check the olenoid Valve 1. Place the system into operation. 2. Trigger the gun using the timer or pattern control. Adhesive flows: Normal indication. Return to the Troubleshooting Table. No adhesive flow: Go to step 3. 3. Manually trigger the gun at the solenoid valve. Adhesive flows: Normal indication. Return to the Troubleshooting Table. No adhesive flow: Go to step 4. 4. Check the solenoid coil for continuity. Continuity ok: Normal indication. Return to the Troubleshooting Table. No continuity: Failed solenoid valve. Replace the solenoid valve. Refer to Repair. NOTE: Verify that the type of solenoid valve being used has a rated service temperature above 85 _C (185 _F). DP2. Check for a Clogged Nozzle or Module Use the following procedure to check an H-200 gun with an extrusion-type nozzle. NOTE: Zero- and reduced-cavity nozzles are not removable. 1. Disable the gun. Refer to afety. 2. Remove the nozzle. 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 or rebuild the module. Refer to Repair.
26 eries H-200 Guns DP3. Check Module Operation NOTE: This procedure assumes that the triggering device and solenoid valve are functioning normally. 1. ee Figure 12. Insert a small Allen wrench or similar probe into the top of the module. 2. Manually trigger the gun at the solenoid valve. The probe moves up and down: Normal indication. Return to the Troubleshooting Table. The probe does not move: Possible failed module. Replace or rebuild the module. Refer to Parts. Figure 12 Checking Module Operation 4201095A DP4. Check the Heater 1. Disable the gun. Refer to afety. 2. Unplug the gun s cordset from the hose. 3. ee Figure 13. Test for continuity across the gun heater circuit (pins 1 and 2). Continuity ok: Normal indication. Return to the Troubleshooting Table. No continuity: The heater is defective. Replace the heater. Refer to Repair. HEATER HEATER RTD RTD GND 1 2 3 5 5 4 2 3 1 4 Figure 13 Gun Cordset Pins 4201096A
eries H-200 Guns 27 DP5. Check the RTD 1. Disable the gun. Refer to afety. 2. Unplug the gun s cordset from the hose. 3. Allow the gun to reach room temperature or use a pyrometer to determine the temperature of the gun. 4. ee Figure 13. When the gun temperature is known, measure the resistance across the RTD circuit (pins 3 and 5). 5. Refer to Figure 14 to determine the expected resistance of the RTD at the known temperature. Compare the expected and measured resistance values. The measured resistance is within the expected range: Normal indication. Return to the Troubleshooting table. The measured resistance is not within the expected range: The RTD is defective. Replace the RTD. Refer to Repair.
28 eries H-200 Guns DP5. Check the RTD(contd) 250 240 230 REITANCE IN OHM 220 210 200 190 180 170 160 150 140 130 16 _C 23 _C 30 _C 37 _C 44 _C 52 _C 59 _C 66 _C 73 _C 81 _C 88 _C 95 _C 102 _C 109 _C 117 _C 60 _F 73 _F 86 _F 99 _F 112 _F 125 _F 138 _F 151 _F 164 _F 177 _F 190 _F 203 _F 216 _F 229 _F 242 _F TEMPERATURE 350 340 330 REITANCE IN OHM 320 310 300 290 280 270 260 250 240 230 131 _C 138 _C 146 _C 153 _C 160 _C 167 _C 174 _C 182 _C 189 _C 196 _C 203 _C 211 _C 218 _C 225 _C 232 _C 268 _F 281 _F 294 _F 307 _F 320 _F 333 _F 346 _F 359 _F 372 _F 385 _F 398 _F 411 _F 424 _F 437 _F 450 _F TEMPERATURE 4207045B Figure 14 RTD Resistance vs. Temperature
eries H-200 Guns 29 Maintenance Table 4 provides the recommended schedule for H-200 gun maintenance. Detailed procedures for weekly and semi-annual maintenance tasks are presented in the remainder of this section. Table 4 H-200 Gun Maintenance chedule Frequency Task Notes Daily Remove hot melt and char from the exterior of the gun assembly. Weekly Clean the gun nozzle(s). A, B Clean or replace the integral filter. B emi-annually Inspect the gun wiring. NOTE A: Nordson recommends the use of nozzle cleaning kit part 901915. B: Process-specific nozzle and filter performance history may indicate the need for more or less frequent nozzle or filter cleaning. Nozzle Cleaning Gun nozzles may become clogged when char, a by-product of overheating the hot melt, becomes lodged in the nozzle. The use of inline or integral filters will significantly reduce nozzle clogging. CAUTION: Do not attempt to clean zero- or reduced-cavity modules. Replace or exchange clogged zero- or reduced-cavity modules. Contact your Nordson representative for information on Nordson s Trade Plust program. 1. Ensure that the gun is at operating temperature. 2. Disable the gun. Refer to afety. 3. ee Figure 15. Remove the nozzle. Figure 15 Removing the Nozzle 4201055
30 eries H-200 Guns Nozzle Cleaning (contd) WARNING: Risk of fire. Do not heat Nordson Type R fluid above 245 _C (475 _F). Use only an industrial grade, regulated, electrical heating devices 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 an unregulated heating device. 4. oak the nozzle(s) in Nordson Type R cleaning fluid that has been heated above the melting point of the hot melt. 5. Remove the nozzle(s) from the cleaning fluid. 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 (P/N 901915) contains a variety of probe sizes. 6. At the outlet of the 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. 8. Reinstall the nozzle(s). Tighten the nozzle(s) to 4.5 Nm (40 in.-lb). Integral Filter Cleaning To speed integral filter maintenance, Nordson recommends that spare filter assemblies (P/N 276754) be kept in stock. 1. Ensure that the gun is at operating temperature. 2. et the pump output to zero, then trigger the gun until the flow of hot melt stops. 3. ee Figure 16. Open the drain valve over a catch pan. Figure 16 Opening the Drain Valve 4201104A
eries H-200 Guns 31 4. Increase the pump output until hot melt flows from the drain. 5. When the hot melt flow is clear, turn the pump off. 6. Relieve system hydraulic pressure and disable the gun. Refer to afety. 7. ee Figure 17. Remove the filter assembly from the manifold body. Figure 17 Removing the Filter Assembly 4201101A 8. ee Figure 18. Disassemble the filter. Figure 18 Filter Components 4201103A
32 eries H-200 Guns Integral Filter Cleaning (contd) WARNING: Risk of fire! Do not heat Nordson Type R fluid above 245 _C (475 _F). Use only an industrial grade, regulated, electrical heating devices 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 with an unregulated heating device. 9. oak the filter components in Nordson Type R cleaning fluid that has been heated above the melting point of the hot melt. 10. Use a non-metallic fine-bristled brush to gently scrub the filter screen. Replace the screen if the mesh is dented or torn. 11. Inspect the O-ring for damage (cuts, nicks, or hardening). Replace the O-ring if it is damaged. 12. Reassemble the filter. CAUTION: Risk of filter damage. Ensure that the gun is at operating temperature before reinstalling the filter assembly. olidified hot melt on the walls of the manifold body can cause the filter screen to collapse if the filter is tightened into a cold manifold body. 13. Bring the gun up to operating temperature. 14. Reinstall the filter assembly, finger tight. 15. Repressurize the system and place the gun back into operation. 16. Increase the pump output until hot melt flows from the drain. 17. Reduce the pump output to zero. 18. Fully tighten the filter assembly. 19. Close the drain valve. 20. Place the system back into operation.
eries H-200 Guns 33 Inspecting the Gun Wiring 1. De-energize the system. Refer to afety. 2. ee Figure 19. Remove the manifold body cover. 3. Check the internal gun wiring for signs of damage and the terminal block connections for tightness. CAUTION: Ensure that the cover gasket on waterwash-style guns is in good condition and properly positioned before replacing the manifold body cover. 4201046 4. Replace the manifold body cover. Figure 19 Removing the Manifold Body Cover Repair This section describes the following H-200 gun repair procedures: Replacing the RTD or Heater Replacing the Module Replacing the Manifold Body Replacing the olenoid Valve Refer to Parts for the repair kits and individual components mentioned in this section. Replacing the RTD or Heater RTDs are hardwired through the gun cordset. If an RTD fails, Nordson recommends that the entire gun cordset be replaced. Heaters are terminated inside the manifold body and can be replaced individually without replacing the entire cordset. The following procedure describes the replacement of an RTD by replacing the entire cordset. Instructions for replacing a heater are also included. To replace an RTD without replacing the entire cordset, use the appropriate RTD replacement kit listed in Parts. The kits contain detailed replacement instructions.
34 eries H-200 Guns Accessing the RTD or Heater 1. De-energize the system and disable the gun. Refer to afety. 2. ee Figure 20. Unplug the gun cordset from the hose. NOTE: tep 3 and 4 are not necessary if the gun is easily accessible and can be serviced without the need to disconnect the hose. 3. (Optional) Relieve system hydraulic pressure. Refer to afety. 4. (Optional) Using two wrenches, disconnect the hose from the gun. 5. Remove the manifold body cover. Figure 20 Accessing the RTD or Heater Replacing the RTD or Heater 1. ee Figure 21. Remove the RTD or heater from the manifold body. 4 3 Figure 21 Gun Wiring 1. Heater 2. RTD 1 2 3. Terminal Block 4. Ground lead 4201098A
eries H-200 Guns 35 2. Disconnect the cordset leads from the terminal block. If the heater is being replaced, disconnect the heater leads from terminal block. 3. ee Figure 21. Do one of the following: To replace the RTD: a. Disconnect the ground lead from the manifold body. b. Remove the cordset from the manifold body cover and replace it with a new cordset. Tighten the cordset locking nut or threaded tension relief. c. Reconnect the ground lead to the manifold body. To replace the heater: a. If necessary, trim the leads of the new heater to match the leads of the old heater. b. Coat the heater with heat-conductive paste (P/N 257 326), then insert the heater into the manifold body. c. Insert each heater lead into the terminal block and tighten the terminal block screws. Wire dual heaters in parallel. NOTE: Refer to Parts for spare terminal blocks. d. Insert the heater leads from the cordset into the terminal block and tighten the terminal block screws. Restoring the ystem to Normal Operation CAUTION: Ensure that the cover gasket on waterwash-style guns is in good condition and properly positioned before replacing the manifold body cover. 1. Replace the manifold body cover. 2. If the hose was removed earlier, use two wrenches to connect the hose to the gun. 3. Plug the gun cordset into the hose. 4. Restore the system to normal operation. Refer to the melter product manual.
36 eries H-200 Guns Replacing the Module 1. Ensure that the gun is at operating temperature. 2. De-energize the system and disable the gun. Refer to afety. 3. ee Figure 22. Remove the module from the manifold body by unscrewing the two socket-head screws from the front of the module. Remove the nozzle if it will be reused. Figure 22 Removing the Module 4201099A CAUTION: Do not allow adhesive to enter the module air passages. Adhesive that enters the air passages will obstruct the flow of air and damage the module. 4. Carefully remove any residual hot melt from the module mounting face. NOTE: If hot melt does enter the air passages, temporarily place the gun into operation, shield the operator, then trigger the gun to expel the hot melt from the air passages. 5. Remove the O-rings from the new module. 6. Lubricate and replace the O-rings. 7. Apply anti-seize compound to the module mounting screws, then reinstall the module on the manifold body. Tighten the screws to 3.3 Nm (30 in.-lb). 8. Install the old nozzle or a new replacement nozzle. Tighten the nozzle to 4.5 Nm (40 in.-lb). 9. Restore the system to normal operation. Replacing the Manifold Body Refer to the instruction sheet (P/N 108575) included with the replacement manifold body. Replacing the olenoid Valve Refer to the instruction sheet (P/N 237513) included with the Nordson replacement valve.