Transcript
TG09 Applicators Customer Product Manual Part 237 507D
NORDSON CORPORATION AMHERST, OHIO USA
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 1999. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice.
Trademarks AquaGuard, Blue Box, Control Coat, Equi=Bead, FoamMelt, FoamMix, Helix, Hot Shot, Hot Stitch, Meltex, MicroSet, MultiScan, Nordson, the Nordson logo, OmniScan, Package of Values, Porous Coat, Posi-Stop, ProLink, PRX, RBX, Shur-Lock, UniScan, UpTime, and Versa-Spray are registered trademarks of Nordson Corporation. BetterBook, CF, Controlled Fiberization, Eclipse, Saturn, Seal Sentry, Swirl Coat, and Vista are trademarks of Nordson Corporation. Never Seez is a registered trademark of Bostik Corporation. Parker Lubricant is a registered trademark of Parker Seal. Viton is a registered trademark of E.I. DuPont de Nemours & Co.
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Table of Contents
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Table of Contents 1. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation and Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . 4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Less-Obvious Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Action in the Event of Unit Malfunction . . . . . . . . . . . . . . . . . . . . . . . 5 Danger of Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Maintenance/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Thermoplastic Hot Melt Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Equipment and Material Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Functional Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Operating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Starting the Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Adjusting the Gun Module Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . 13 Flushing the Manifold Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Shutting Down the Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Changing Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 4. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Scheduling Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Cleaning the Manifold Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Cleaning the Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Inspecting the Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . 22
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Table of Contents 5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Troubleshooting Adhesive Application Problems . . . . . . . . . . . . . 23 Troubleshooting Heating Problems . . . . . . . . . . . . . . . . . . . . . . . . . 26 Troubleshooting Pump Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Heater Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Thermostat Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Solenoid Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Air Regulator Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Gun Body Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nozzle Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Pump Siphon Ball Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Replacing a Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Over-Temperature Thermostat Replacement . . . . . . . . . . . . . . 33 Tank Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Gun Body Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . 37 Replacing the Gun Body Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Replacing a Gun Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Replacing the Manifold Filter Screen . . . . . . . . . . . . . . . . . . . . . . . 42 Replacing or Servicing the Piston Pump . . . . . . . . . . . . . . . . . . . . 45 Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Crossover Tube O-Ring and Back-Up Ring Replacement . . . 47 Check Valve Ball and Seat Replacement . . . . . . . . . . . . . . . . . 47 Siphon Ball Cage and Seat Assembly Replacement . . . . . . . . 47 Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 System Restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Replacing the Gun Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Gun Body Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Gun Body Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 System Restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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7. Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Using the Illustrated Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Recommended Spare Parts and Supplies . . . . . . . . . . . . . . . . . . . 54 TG09 Applicators and Installation Kits . . . . . . . . . . . . . . . . . . . . . . 55 TG09 Applicator Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Common Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Right-Hand and Left-Hand Applicators . . . . . . . . . . . . . . . . . . . 60 Piston Pump Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Manifold Filter Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Gun Module and Nozzle Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . 67 Gun Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Solenoid Valve Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 8. Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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Table of Contents
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Introduction
O-1
Order Form To order additional product manuals and operator cards, send this form to your local Nordson representative or contact one of the Nordson Customer Service Centers. Send copies to: Name
____________________________________________
Department ____________________________________________ Company
____________________________________________ ____________________________________________
Address
____________________________________________ ____________________________________________
Phone
________________ Fax _______________________
Number of Copies
Part Number
Product Manual Operators Card
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O1EN–OPC–[ORDER]–ST Issue 2/97
O-2
Introduction
O1EN–OPC–[ORDER]–ST
Issue 2/97
1997 Nordson Corporation All rights reserved
TG09 Applicators
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TG09 Applicators WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation.
1. Safety
Safety instructions contained in this section and throughout this document apply to tasks that may be performed with or on the unit. Warnings related to specific safety concerns are included within the text as appropriate. It is very important that these safety instructions are always followed. Failure to do so could result in personal injury and/or damage to the unit or other equipment. With this in mind, here are some basic safety recommendations:
Read and become familiar with this Safety section prior to installing, operating, maintaining, or repairing the unit.
Read and follow the warnings which appear within the text and are related to specific tasks.
Store this document within easy reach of personnel operating or maintaining the unit.
Wear personal protective equipment and clothing such as safety goggles and gloves.
Familiarize yourself with and follow all safety instructions prescribed by your company, general accident-prevention regulations, and government safety regulations.
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TG09 Applicators
Safety Symbols
The following symbols are used to warn against dangers or possible sources of danger. Become familiar with them! Failure to heed a warning could lead to personal injury and/or damage to the unit or other equipment. WARNING: Failure to observe may result in personal injury, death, or equipment damage.
WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage.
WARNING: Disconnect equipment from the line voltage.
WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and/or heat-protective gloves depending on the symbols shown.
WARNING: Risk of explosion or fire. Fire, open flames, and smoking prohibited.
WARNING: System or material pressurized. Relieve pressure. Failure to observe may result in serious burns.
CAUTION: Failure to observe may result in equipment damage.
CAUTION: Hot surface. Failure to observe may result in burns.
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Qualified Personnel
“Qualified personnel” is defined here as individuals who thoroughly understand the equipment and its safe operation, maintenance, and repair. Qualified personnel are physically capable of performing the required tasks, familiar with all relevant safety rules and regulations, and have been trained to safely install, operate, maintain, and/or repair the equipment. It is the responsibility of the company operating the equipment to see that its personnel meet these requirements.
Intended Use
The unit is designed and intended to be used only for the purpose described in the Description section. Uses not in accordance with that section or as described in this document are considered unintended uses and not in accordance with governing regulations. WARNING: Use of this equipment in ways other than described in this document may result in personal injury, death, or equipment damage. The following actions of the owner or operator of the unit are some, but not all, examples of unintended use which would permit Nordson to claim it is not responsible for personal injury or property damage arising from such unintended use:
Unapproved modifications or changes to the unit Failure to comply with the safety instructions Failure to comply with instructions concerning installation, use,
operation, maintenance, or repair, or when these tasks are carried out by unqualified personnel
Use of inappropriate or incompatible foreign materials or auxiliary equipment
Failure to observe workplace safety rules or regulations issued by government authorities or safety councils
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Installation and Electrical Connections
WARNING: Failure to follow the safety procedures can result in injury or death.
All electrical, pneumatic, gas, and hydraulic connections and
installations of hot melt equipment may only be carried out by qualified personnel. Be sure to observe installation instructions for components and accessories.
Equipment must be properly grounded and fused according to its rated current consumption (see ID plate).
Cables which run outside the unit must regularly be checked for wear or damage.
Power supply wire gauge and insulation must be sufficient to handle rated current consumption.
Cables must never be squeezed or pinched. Do not locate cables or hoses in high traffic areas.
Operation
The unit should be operated by qualified personnel in accordance with the instructions presented in this document. WARNING: Failure to follow the safety procedures can result in injury or death.
Never allow the unit to be operated by personnel under the influence of substances which reduce their reaction times, or who are not able to operate the equipment for physical reasons.
Prior to each start-up of the unit, check protection and warning
devices and make sure they are fully functional. Do not operate the unit if these devices are not functioning properly.
When the removal of safety equipment is required for installation, maintenance, or repair of the unit, it must be re-connected immediately upon completion of the work.
Prior to start-up of the unit, check to make sure all safety guards and safety equipment are in place and functioning properly.
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In a humid environment, only equipment featuring a corresponding class of protection may be operated.
Do not operate the unit in an explosive environment. Keep parts of the body or clothing away from rotating parts. Do not
wear loose articles of clothing when operating or servicing units with rotating parts. Take off wrist watches, rings, necklaces, or similar pieces of jewelry and pin up or cover long hair before performing any work on or with the unit.
To carry out measurements on work pieces, switch off the unit and wait until it comes to a standstill.
Never point hand guns or applicator nozzles at yourself or other persons.
Less-Obvious Dangers
WARNING: An operator or service technician working with the unit should be aware of less-obvious dangers that often cannot be completely minimized at production sites:
Exposed surfaces of the unit which cannot be practically
safeguarded. They may be hot and take time to cool after the unit has been operating.
The possibility that electrical potentials may remain in the unit after the unit was de-energized
Hot melt material and vapors Hydraulically or pneumatically operated parts of the unit Parts winding something up or down which are not covered
Action in the Event of Unit Malfunction
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If the unit malfunctions, switch it off immediately.
Turn the circuit breaker or main power switch OFF. Have the unit repaired by qualified personnel only.
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Danger of Burns
Contact with hot melt materials or hot areas of the unit may produce a severe skin burn. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and/or heat-protective gloves depending on the symbols shown.
Be extremely careful when using hot melt material. Even solidified material may still be very hot.
Always wear protective clothing which safely covers all exposed parts of the body.
In case of burns:
Immediately cool affected skin areas using cold, clean water. Do not forcefully remove hot melt material from the skin. Immediately seek medical attention. Maintenance/Repair
Allow only qualified personnel to perform the procedures described in this document. When performing such tasks, wear protective clothing, and equipment. WARNING: Even when the circuit breaker or main power switch is OFF, the unit is still electrically energized. Complete the following steps prior to maintenance or repair:
Disconnect, lock out, and tag external power supply. To ensure the external power supply is disconnected, attempt to operate the unit. If the unit does not energize, proceed with maintenance or repair work.
If the unit energizes, repeat the disconnect, lock out, and tag procedure. Re-test the unit.
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Follow the specific instructions provided in this manual to relieve the system pressure in the entire unit.
Secure pneumatically-or hydraulically-operated equipment against uncontrolled movement.
Only use parts which do not compromise the safety of the unit. Only use genuine Nordson parts.
Always use tools with insulated handles when removing or installing components.
Cleaning
NOTE: Always refer to the material manufacturer’s Material Safety Data Sheet (MSDS) or material information sheet before working with any material. WARNING: Never clean any aluminum part or flush any system using halogenated hydrocarbon fluids. Examples of common halogenated hydrocarbons are: dichloromethylene, 1,1,1-trichloroethylene, and perchloroethylene. Halogenated hydrocarbons may react violently with aluminum parts. WARNING: Fire, open flame, and smoking are prohibited when cleaning fluids are used. Observe all explosion prevention regulations. Cleaning fluids may only be heated using temperature-controlled and explosion-protected heaters.
Never use an open flame to clean the unit or components of the unit. Use only cleaning fluids designed or intended to be used with the hot
melt material being used in the unit. Never use paint fluids under any circumstances.
Note the flash point of the cleaning fluid used. Only use a controlled heating method to heat fluids.
Ensure sufficient room ventilation to draw off generated vapors. Avoid prolonged breathing of vapors.
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TG09 Applicators
Thermoplastic Hot Melt Material
NOTE: Always refer to the material manufacturer’s Material Safety Data Sheet (MSDS) or material information sheet before working with any hot melt material.
Ensure the work area is adequately ventilated. Do not exceed recommended processing temperatures. Doing so
creates a danger to personnel due to decomposition of the material.
Equipment and Material Disposal
Dispose of equipment and materials used in operation and cleaning according to local regulations.
2. Description
This manual contains operating, maintenance, troubleshooting, repair, and part number information for TG09 applicators. NOTE: Instructions for installing TG09 applicator systems are contained in the TG09 applicator installation kits. Refer to Parts for installation kit part numbers. See Figure 1. The Nordson TG09 applicator melts adhesive and pumps it through a manifold and gun body to gun modules. The pump and gun modules operate as air-open, spring-close. The applicator’s temperature controls allow you to adjust the operating temperature setpoints for the tank and the gun body. A pattern controller sends signals to trigger the guns to deposit adhesive.
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TG09 Applicators
2
3 4
5
1 6
7 8
14
13
10 12
9
11
4151001
Fig. 1 TG09 Applicator System Components 1. 2. 3. 4. 5.
TG09 applicator Pump cover Gun body Gun modules Product sensor (optical sensor)
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6. 7. 8. 9. 10.
Encoder (optional) Air regulators Pattern controller Gun solenoid valve Circuit breaker
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11. 12. 13. 14.
Gun body temperature control PUMP CYCLE push-button Manifold filter and drain valve Tank temperature control
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TG09 Applicators
Functional Operation
The TG09 applicator is designed to be installed on an SWF Traymatic or Blissmatic box-forming machine and to apply adhesive to the flaps of box blanks before they are formed into boxes. The applicator is assembled in left-hand and right-hand configurations, with one of each mounted on the parent machine. The applicator consists of a 9-L (18-lb) tank with an integral manifold and gun body that feed adhesive gun modules without using hot melt hoses. There are two bulb-and-capillary temperature controllers, one for the tank and one for the end of the gun body. To ensure safe operation, an overtemperature thermostat is mounted on the tank wall. The tank has an integral cast-in heater and the gun body has a cartridge heater. The applicator is equipped with a single-acting piston pump. The pump and the gun modules are air-driven by solenoid valves. When the applicator is turned on at the circuit breaker, a green SYSTEM POWER light illuminates, indicating that power is on inside the enclosure. A yellow light for each temperature zone will illuminate while the corresponding zone is heating and will cycle on and off when that zone reaches the temperature set on the accompanying dial. The temperature in each zone can be set between 93 and 204 C (200 and 400 F). If the tank temperature reaches 232 C (450 F), the overtemperature thermostat will cause the applicator to shut down. The pump and gun modules require air pressure and control signals to operate. A product sensor and pattern control system provide the signals that apply the air pressure. When the signals are removed, the pump and gun springs return the components to their inactive states. A manual push-button is included on the applicator to operate the pump when the applicator is being drained or when the filter is being flushed of impurities. During normal operation, a sensor detects the leading edge of a box blank and sends a signal to the pattern control system. The pattern control system sends signals to the pump solenoid valve and the gun module solenoid valves. The gun body includes air manifolds which cause the gun modules to deposit the desired adhesive pattern on the box blank.
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TG09 Applicators Specifications Item
Description
Specification
Note
Weight of empty unit
34 kg (76 lb)
Melt rate
8 kg/hr (17 lb/hr)
Workplace temperature range
0–38 C (32–100 F)
Electrical service
200–250 Vac
Maximum applicator power capacity at 230 Vac
13.5 A (each)
Recommended fuse size at 230 Vac
20 A (each)
Control temperature range
93–205 C (200–400 F)
Overtemperature protection
232 C (450 F) thermostat
Tank
Capacity
9 l (approximately 18 lb)
Pump
Air pressure while running
241–379 kPa (35–55 psi)
Hydraulic pressure (maximum while running)
3,800 kPa (550 psi)
Air consumption at 345 kPa (50 psi) and maximum pump speed
9.2 l/min (0.326 standard ft3/min)
Displacement (maximum)
35 ml/stroke (2.14 in.3/stroke)
Output rate (maximum instantaneous)
680 kg/min (1.5 lb/min)
Air pressure while running
345–552 kPa (50–80 psi) (each)
Air consumption at 414 kPa (60 psi) and maximum pump speed
11.8 l/min (0.417 standard ft3/min) (four gun modules)
General
Electrical/Controls
Guns
A
A
NOTE A: Based on a material with a specific gravity of 0.84.
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TG09 Applicators
3. Operation
Operating Guidelines
This section contains operating guidelines and procedures for installed TG09 applicators. Instructions for installing TG09 applicator systems are contained in the TG09 applicator installation kits. Refer to Parts for installation kit part numbers.
The following operating guidelines are recommended by Nordson Corporation to obtain the best and most consistent applicator performance.
Keep the applicator tank at least half full of adhesive except when the applicator must be shut down for material change or flushing.
To prevent the adhesive supply from becoming contaminated, store
fresh adhesive material in a closed container. Foreign material entering the tank can lodge in the pump and cause equipment failure or improper operation.
Keep the product (cardboard) at room temperature, dry, and free of dust and grease.
Refer to the adhesive supplier’s material information sheet or Material Safety Data Sheet (MSDS) when determining the operating temperature setpoints for an adhesive.
Avoid heating adhesive above the recommended operating
temperature. Higher temperatures can cause char or generate dangerous vapors. WARNING: Risk of personal injury. Do not operate the hot melt system at pressures higher than necessary for optimum system performance. Doing so can harm personnel or equipment and cause poor pattern control.
The recommended pump air pressure range is 241–379 kPa (35–55 psi).
The recommended gun air pressure range is 345–552 kPa (50–80 psi).
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TG09 Applicators Starting the Applicators
Use this procedure to turn on the applicators. See Figure 1 for component locations. 1. Turn on power to the applicators. The green SYSTEM POWER light will turn on. 2. Make sure the temperature controls are set to the desired operating temperature setpoints. 3. If needed, fill the tanks with adhesive to within 25 mm (1 in.) of the top of the tank. 4. Turn on the operating air for the pumps and the guns. 5. Turn on the pattern controller. 6. Wait for the yellow lights on each applicator to begin cycling (turning on and off). The lights will begin cycling in 30 to 40 minutes. The applicators are ready for operation.
Adjusting the Gun Module Nozzles
See Figure 2. Use a wrench to adjust the direction of the gun module nozzles as needed.
4151002
Fig. 2 Adjusting a Right-Angle Nozzle
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TG09 Applicators
Flushing the Manifold Filter
Nordson Corporation recommends flushing the manifold filter on each applicator once each day. WARNING: Risk of burns. Do not use the pattern controller to trigger the guns. Doing so can cause unexpected pressure buildup. 1. Relieve pressure in the gun body by manually activating one gun solenoid valve. 2. Reduce the pump air pressure to about 69 kPa (10 psi). 3. See Figure 3. Open the drain valve.
4151003
Fig. 3 Opening the Drain Valve
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TG09 Applicators 4. Hold a drain pan under the drain valve. WARNING: Hot! Risk of burns. Wear safety goggles and heat-protective gloves.
5. See Figure 4. Press, hold, and release the PUMP CYCLE push-button repeatedly until the adhesive flowing from the drain valve is clear. 6. Close the drain valve. 7. Restore the pump air pressure to the normal setting.
4151004
Fig. 4 Draining Adhesive
Shutting Down the Applicators
Use this procedure to turn off the applicators. 1. Turn off the pattern controller. 2. Turn off the operating air for the pumps and the guns. 3. Turn off power to the applicators.
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TG09 Applicators
Changing Adhesives
When changing adhesives, contact your adhesive supplier about the compatibility of the old and new adhesives. If the old and new adhesives are compatible, add the new adhesive to the tank. If the old and new adhesives are not compatible, follow this procedure to flush the system before using the new adhesive. 1. Contact your adhesive supplier to determine the correct flushing agent to use. 2. Make sure the applicators are at operating temperature. 3. Pump flushing agent through the applicators until no trace of adhesive flows from the gun modules. NOTE: The flushing agent has reached the gun modules when the adhesive color and viscosity begin to change. 4. Fill the applicators with the new adhesive and run the pumps until no trace of flushing agent flows from the gun modules. 5. Resume normal operation.
4. Maintenance
Use these maintenance procedures to properly maintain your TG09 applicators. WARNING: Attempting any other maintenance procedures can result in equipment damage, improper system operation, or personal injury.
Scheduling Maintenance
Table 1 provides a recommended schedule for TG09 applicator maintenance. Table 1 Maintenance Schedule Frequency Weekly
Maintenance Activity Clean the manifold filter unless operational history indicates more or less frequent cleaning is required. Clean the nozzles unless operational history indicates more or less frequent cleaning is required.
Semiannually
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Inspect the electrical connections.
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TG09 Applicators Cleaning the Manifold Filter
Use this procedure to clean the manifold filter components, including the screen. 1. Make sure the applicator is at operating temperature. WARNING: Risk of burns. Do not use the pattern controller to trigger the guns. Doing so can cause unexpected pressure buildup. 2. Relieve pressure in the gun body by manually activating one gun solenoid valve. 3. See Figure 5. Unscrew the filter assembly and remove it from the manifold. NOTE: The steel filter adapter remains in the manifold.
4151005
Fig. 5 Removing the Manifold Filter
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TG09 Applicators
Cleaning the Manifold Filter (contd.)
4. See Figure 6. Follow these steps to disassemble the filter. a. Remove the screw (5) from the bung (1). b. Slide the screen (4) off and discard it. c. Slide a new screen onto the core (3). d. Reassemble the filter.
4 3
ÎÎÎÎÎÎ ÎÎÎÎÎÎ ÎÎÎÎÎÎ ÎÎÎÎÎÎ
2 1 5
4151006
Fig. 6 Filter Components 1. Bung 2. O-ring 3. Core
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4. Screen 5. Screw
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5. Use one of the following methods to clean the filter components. WARNING: Risk of fire or explosion. Do not heat Nordson Type-R cleaning fluid above 246 C (475 F). Do not heat cleaning fluid with an open flame or in an unregulated heating device. Use only a controlled heating device, such as a small, deep fat fryer or thermostatically controlled hot plate, to heat the fluid above the adhesive’s melting temperature.
CAUTION: Do not use a metal brush to clean the filter screen. Doing so can damage the screen and prevent the filter from operating properly.
Place the filter components, except for the O-ring, in a container
of Type-R cleaning fluid and heat the fluid until it is above the melting point of the adhesive. Scrub the filter components with a fine-bristled brush until the filter assembly is clean. Remember to scrub the filter screen inside and out. Wipe the components with a clean, dry cloth.
Use a flameless, electric heat gun or compressed hot air to heat the filter components. Wipe the components with a clean, dry cloth.
Use an ultrasonic cleaner filled with cleaning fluid to soak the filter components, then wipe the components with a clean, dry cloth.
6. Inspect the filter screen for damage. A dent or break in the mesh means that the screen is damaged beyond repair and should be replaced. Refer to Repair for the filter screen replacement procedure. CAUTION: Make sure the applicator is at operating tempertaure before reinstalling the filter. Cold material from the filter or manifold walls can cause the filter screen to collapse if it is tightened in a cold system. 7. See Figure 6. Reassemble the filter; then screw it into the manifold only until it seats. Do not over-tighten.
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TG09 Applicators
Cleaning the Nozzles
Nozzle clogging occurs when a manifold filter screen is damaged or when there is charred material in the manifold or gun body. Char may occur if adhesive is heated above the operating temperature recommended by the adhesive manufacturer. WARNING: Risk of burns. Do not use the pattern controller to trigger the guns. Doing so can cause unexpected pressure buildup. 1. Relieve pressure in the gun body by manually activating one gun solenoid valve. WARNING: Disconnect equipment from line voltage. Failure to observe this warning could result in severe personal injury or death. 2. Disconnect and lock out power to the applicator. 3. See Figure 7. Use a 5/32 nut driver (1) or socket to unscrew the nozzle (2) from the nozzle adapter (3); then unscrew the adapter from the gun module (4).
4
1 2 3 4151007
Fig. 7 Removing a Right-Angle Nozzle 1. Nut driver 2. Nozzle
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3. Nozzle adapter 4. Gun module
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4. Use one of the three following methods to clean nozzle components: WARNING: Risk of fire or explosion. Do not heat Nordson Type-R cleaning fluid above 246 C (475 F). Do not heat cleaning fluid with an open flame or in an unregulated heating device. Use only a controlled heating device, such as a small, deep fat fryer or thermostatically controlled hot plate, to heat the fluid above the adhesive’s melting temperature.
Place the nozzle components in a container of Type-R cleaning
fluid and heat the fluid until it is above the melting point of the adhesive. Scrub the nozzle components with a fine-bristled brush until they are clean. Wipe the components with a clean, dry cloth.
Use a flameless, electric heat gun or compressed hot air to heat the nozzle components. Wipe the components with a clean, dry cloth.
Use an ultrasonic cleaner filled with cleaning fluid to soak the
nozzle components, then wipe the components with a clean, dry cloth.
5. Use a pin-type probe to clean the nozzle passage-ways. Nordson offers a nozzle-cleaning kit that contains a holder and a variety of probes. Refer to Parts for the part number. CAUTION: Risk of equipment damage. Do overtighten a nozzle. Overtightening can cause equipment damage or nozzle leakage. 6. Reassemble the nozzle adapter onto the gun module, then screw the nozzle into the nozzle adapter. Tighten the nozzle to 0.46 Nm (4.0 in.-lb). 7. Restore the system to normal operation.
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TG09 Applicators
Inspecting the Electrical Connections
Use this procedure to inspect the electrical connections. For your information, wiring diagrams are included at the end of this manual. WARNING: Disconnect equipment from line voltage. Failure to observe this warning could result in severe personal injury or death. 1. Disconnect and lock out power to the applicator. 2. See Figure 8. Remove the electrical access panel (1).
1 2
4151025
Fig. 8 Removing the Electrical Access Panel 1. Electrical access panel
2. Securing screws
3. Inspect the electrical connections. Tighten any loose connections. 4. Make sure the tank heater wires are securely attached to the tank heater contacts. 5. Make sure all wire nuts are secure. 6. Reattach the electrical access panel to the applicator with the screws removed earlier. 7. Restore power to the applicator and resume normal operation.
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The following troubleshooting tables describe the kinds of problems you may encounter and provide corrective actions for handling those problems. When necessary, the tables refer to more detailed troubleshooting procedures.
5. Troubleshooting
Refer to the appropriate troubleshooting table for the type of problem you are experiencing. This part of the manual contains the following troubleshooting tables:
Troubleshooting Adhesive Application Problems Troubleshooting Heating Problems Troubleshooting Pump Problems Troubleshooting Adhesive Application Problems Problem
Possible Cause
Corrective Action
1. Desired adhesive output
Applicator working properly
None.
2. No adhesive output
Applicator not turned on
Make sure power is being supplied to the applicators.
Operating air not turned on
Make sure the operating air for the pump and guns is turned on.
Pattern controller not turned on
Make sure the pattern controller is turned on.
Faulty trigger signal
Check the trigger signal. If the triggering device is a photo-eye, pass a solid object in front of the photo-eye.
Adhesive too cold
Adjust the operating temperature setpoints.
Faulty gun or pump solenoid valve
Manually trigger the solenoid valve. If it does not trigger, check the resistance. Refer to Solenoid Valve Check. Continued on next page
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TG09 Applicators
Troubleshooting Adhesive Application Problems (contd.) Problem 3. Not enough adhesive
4. Adhesive pooling at beginning or end of bead
Possible Cause
Corrective Action
Operating air pressure too low
Adjust the operating air pressure for the pump as needed.
Adhesive too cold
Adjust the operating temperature setpoints.
Manifold filter clogged
Flush the manifold filter. Refer to Flushing the Manifold Filter in the Operation section.
Gun body clogged
Check for a clogged gun body. Refer to Gun Body Check.
Nozzle clogged
Check for a clogged nozzle. Refer to Nozzle Check.
Nozzle partially clogged
Clean the nozzle or nozzles. Refer to Cleaning the Nozzles in the Maintenance section.
Continued on next page
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TG09 Applicators
Problem
Possible Cause
25
Corrective Action
Operating air pressure too high
Adjust the operating air pressure for the pump as needed.
Adhesive too hot
Adjust the operating temperature setpoints.
6. Missing bead
One gun nozzle clogged
Clean the nozzle. Refer to Cleaning the Nozzles in the Maintenance section.
7. Misplaced bead
Gun nozzle pointing in the wrong direction
Adjust the gun nozzle.
8. Wavy beads
Adhesive too cold
Adjust the operating temperature setpoints.
Product not feeding straight
Check the product feed.
5. Too much adhesive
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TG09 Applicators
Troubleshooting Heating Problems Problem Tank or gun body fails to heat or under-heats
Possible Cause
Corrective Action
Failed tank or gun body heater
Check the heater. Refer to Heater Check.
Failed tank or gun body thermostat
Check the thermostat. Refer to Thermostat Check.
Tank or gun body operating temperature setpoint too low
Adjust the tank or gun body temperature setpoint.
Possible Cause
Corrective Action
Troubleshooting Pump Problems Problem 1. Pump not stroking
2. Pump stroking erratically
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Operating air pressure too low
Adjust the operating air pressure for the pump.
Failed pump air regulator
Check the air regulator. Refer to Air Regulator Check.
Failed pump solenoid valve
Check the solenoid valve. Refer to Solenoid Valve Check.
Blockage in adhesive channel upstream of drain valve
Remove and clean the manifold filter screen. Refer to Cleaning the Manifold Filter in the Maintenance section.
Adhesive level too low
Check the adhesive level. Add adhesive if needed.
Adhesive too cold
Adjust the operating temperature setpoints.
Pump siphon ball not seating
Check the siphon ball. Refer to Pump Siphon Ball Check.
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TG09 Applicators Troubleshooting Procedures
27
Use the following procedures as directed in the troubleshooting tables to further diagnose applicator problems.
Heater Check Follow this procedure to check a tank or gun body heater. WARNING: Disconnect equipment from line voltage. Failure to observe this warning could result in severe personal injury or death. 1. Turn off and lock out power to the applicator. 2. Remove the electrical access panel. 3. Use a standard multi-meter to test the tank or gun body heater at the heater wires.
Tank heater resistance reading of 17–20 ohms: normal indication. Return to the troubleshooting tables.
Tank heater resistance reading outside 17–20 ohms: Failed tank heater. The TG09 applicator tank has cast-in heaters. If a tank heater fails, you must replace the entire tank. Contact your Nordson representative for assistance.
Gun body heater resistance reading of 104–121 ohms: normal indication. Return to the troubleshooting tables.
Gun body heater resistance reading outside 104–121 ohms:
Failed gun body heater. Replace the heater. Refer to Replacing the Gun Body Heater in the Repair section.
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TG09 Applicators Thermostat Check Follow this procedure to check a tank or gun body thermostat. WARNING: Disconnect equipment from line voltage. Failure to observe this warning could result in severe personal injury or death. 1. Turn off and lock out power to the applicator. 2. Remove the electrical access panel. 3. Check continuity across the tank or gun body thermostat while rotating the tank or gun body temperature control knob.
Continuity until setting reaches actual tank temperature, then
open circuit: normal indication. Return to the troubleshooting tables.
Continuity through entire range of adjustment: failed thermostat. Replace the thermostat. Refer to Replacing a Thermostat in the Repair section.
Solenoid Valve Check Follow this procedure to check a pump or gun solenoid valve. Solenoid valves must meet high-temperature specifications. Refer to the Parts section for the part number of a solenoid valve suitable for use at service temperatures above 85 C (185 F). 1. Make sure the applicator is at operating temperature and that the air supply to the solenoid valve is turned on. WARNING: Risk of burns. Do not use the pattern controller to trigger the guns. Doing so can cause unexpected pressure buildup. 2. Trigger the guns by manually activating the gun solenoid valve while also pressing the PUMP CYCLE push-button.
Adhesive flows from the gun module: normal indication. Return to the troubleshooting tables.
No adhesive flows and no clicking sound: electrical problem or insufficient air pressure to the solenoid valve. Continue to the next step.
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3. Disconnect the wires to the solenoid valve. 4. Connect a standard ohmmeter across the solenoid valve.
Continuity exists: normal indication. Return to the troubleshooting tables.
No continuity: defective solenoid valve. Replace the solenoid valve.
Air Regulator Check Follow this procedure to check a pump or gun air regulator. 1. Turn off the air regulator. 2. Turn off the air to the regulator at the air supply source. 3. Disconnect the solenoid valve air line from the air regulator. 4. Restore air pressure to the regulator. 5. Gradually turn on the air regulator to verify that air is flowing through the regulator.
No air flows from the regulator: regulator defective. Replace the regulator.
Air flows from the regulator: normal indication. Return the air
pressure to 0, reconnect the air regulator to the solenoid valve, and return to the troubleshooting tables.
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TG09 Applicators Gun Body Check Follow this procedure to check for a clogged gun body. 1. Turn off the operating air to the pump. WARNING: Risk of burns. Do not use the pattern controller to trigger the guns. Doing so can cause unexpected pressure buildup. 2. Relieve pressure in the gun body by manually activating one solenoid valve. 3. Remove a gun module from the gun body. 4. Place a drain pan below the gun body. 5. Set the pump air pressure at about 69 kPa (10 psi). 6. Press, hold, and release the PUMP CYCLE push-button.
Adhesive flows from the gun body: normal indication. Return to the troubleshooting tables.
No adhesive flows from the gun body: gun body clogged.
Replace the gun body. Refer to Replacing the Gun Body in Repair.
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Nozzle Check Follow this procedure to check for a clogged nozzle. 1. Turn off the operating air to the guns. WARNING: Risk of burns. Do not use the pattern controller to trigger the guns. Doing so can cause unexpected pressure buildup. 2. Relieve pressure in the gun body by manually activating one solenoid valve. 3. Reduce the pump air pressure to about 69 kPa (10 psi). 4. Use a 5/32 nut driver or socket to remove the right-angle nozzle from the nozzle adapter. 5. Slowly restore air pressure to the gun solenoid valve to about 276–345 kPa (40–50 psi). 6. Trigger the guns by manually activating the gun solenoid valve while also pressing the PUMP CYCLE push-button.
Adhesive flows from adapter: nozzle clogged. Replace the nozzle.
No adhesive flows from adapter: gun body may be clogged. Go to Gun Body Check.
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TG09 Applicators Pump Siphon Ball Check Follow this procedure to check the pump siphon ball. WARNING: Risk of burns. Do not use the pattern controller to trigger the guns. Doing so can cause unexpected pressure buildup. 1. Increase and decrease the pump air pressure while triggering the guns by manually activating one solenoid valve. This tends to dislodge particles that prevent the siphon ball from resting on the ball seat. 2. If the pump begins operating smoothly, resume normal operation. If not, continue to the next step. 3. Remove the pump cover. 4. Remove the pump. Refer to Pump Removal in the Repair section. 5. See Figure 9. Remove the siphon ball seat (3), siphon ball (2), and siphon ball cage (1) from the bottom of the pump body. NOTE: Use an electric heat gun to warm the pump body if the adhesive has solidified and prevents removal of these components. 6. Remove any char or debris from the bottom of the pump body and siphon ball assembly. 7. Reassemble the siphon ball cage (1), siphon ball (2), and siphon ball seat (3) into the bottom of the pump body. 8. Reassemble the pump and reinstall the pump assembly in the applicator. Refer to Pump Installation in the Repair section. 1 2 3
4151024A
Fig. 9 Pump Siphon Ball Assembly Components 1. Siphon ball cage 2. Siphon ball 3. Siphon ball seat
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TG09 Applicators
6. Repair
33
The Troubleshooting section contains diagnostic procedures which may identify failed components. This section contains repair procedures for the following components:
Thermostats (overtemperature, tank, and gun body) Gun body heater Gun modules Manifold filter screen Piston pump Gun body
Refer to Parts to locate and order replacement parts and service kits. You can use parts lists drawings as a guide as you perform the following repair procedures.
Replacing a Thermostat
Use these procedures to replace a failed over-temperature, tank, or gun body thermostat. The over-temperature thermostat and tank thermostat sensor (bulb) are mounted on the tank wall. The gun body thermostat sensor (bulb) is housed in a groove under the gun body.
Over-Temperature Thermostat Replacement The over-temperature thermostat is a button thermostat that is mounted on the tank wall with two screws. WARNING: Disconnect equipment from line voltage. Failure to observe this warning could result in severe personal injury or death. 1. Turn off and lock out power to the applicator. 2. Remove the pump cover. 3. Remove the screws that secure the tank enclosure to the applicator; then remove the tank enclosure, guiding it carefully past the pump. 4. Fold back the tank insulation to expose the overtemperature thermostat.
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TG09 Applicators Over-Temperature Thermostat Replacement (contd.) 5. See Figure 10. Remove the two screws (2) that secure the thermostat, then remove the thermostat (1).
1
2
4151009
Fig. 10 Replacing the Over-Temperature Thermostat 1. Thermostat
2. Screws
6. Cut the wires at the old thermostat, then use the wire nuts from the service kit to attach the new thermostat wires to the existing wires. 7. Coat the mounting surface of the new thermostat with thermal joint compound. 8. Secure the thermostat in place on the tank using the two screws. 9. Place the insulation back over the thermostat; then reinstall and secure the tank enclosure 10. Reinstall the pump cover. 11. Resume normal operation.
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TG09 Applicators Tank Thermostat Replacement The tank thermostat is a bulb-and-capillary-tube thermostat.
WARNING: Disconnect equipment from line voltage. Failure to observe this warning could result in severe personal injury or death. 1. Turn off and lock out power to the applicator. 2. Remove the pump cover. 3. Remove the screws that secure the tank enclosure to the applicator; then remove the tank enclosure, guiding it carefully past the pump. 4. Fold back the tank insulation to expose the thermostat bulb clamp. 5. See Figure 11. Remove the screws (3) that secure the thermostat bulb clamp (2) to the tank wall. Remove the bulb clamp and the thermostat bulb (1) together.
2
1
3
4151010
Fig. 11 Removing the Tank Bulb-and-Capillary-Tube Thermostat 1. Thermostat bulb 2. Thermostat bulb clamp
3. Screws
6. See Figure 12. Pull the knob (1) off the thermostat body (3). 7. Remove the screws that secure the thermostat body (3) and bezel (2) to the applicator base and pull the thermostat body away from the base.
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TG09 Applicators Tank Thermostat Replacement (contd.)
3
2 1
4 5
4151011
Fig. 12 Bulb-and-Capillary-Tube Thermostat Components 1. Knob 2. Bezel 3. Body
4. Capillary tube 5. Bulb
8. Disconnect the wires and remove the thermostat from the applicator. 9. Slide the sleeving off the old thermostat bulb-and-capillary tube. 10. Slide the sleeving onto the new thermostat bulb-and-capillary tube. 11. Connect the wires to the new thermostat body. 12. Secure the new thermostat and the bezel to the applicator base using the screws you removed earlier. 13. Push the knob onto the shaft. 14. Coat the thermostat bulb with thermal joint compound. 15. Place the thermostat bulb and clamp against the tank wall and secure them with the screws you removed earlier. 16. Reinstall and secure the tank enclosure. 17. Reinstall the pump cover. 18. Resume normal operation.
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TG09 Applicators Gun Body Thermostat Replacement The gun body thermostat is a bulb-and-capillary-tube thermostat.
WARNING: Disconnect equipment from line voltage. Failure to observe this warning could result in severe personal injury or death. 1. Turn off and lock out power to the applicator. 2. See Figure 13. Remove the gun body thermostat bulb cover (3). 3. Remove the pump cover. 4. Remove the screws (2) that secure the tank enclosure (1) to the applicator; then remove the tank enclosure, guiding it carefully past the pump.
1 2
4
3
4151012A
Fig. 13 Removing the Gun Thermostat 1. Tank enclosure 2. Screw
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3. Gun body thermostat bulb cover 4. Thermostat bulb
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TG09 Applicators Gun Body Thermostat Replacement (contd.) 5. See Figure 14. Pull the knob (1) off the thermostat body (3). 6. Remove the screws that secure the thermostat body (3) and bezel (2) to the applicator base and pull the thermostat body away from the base.
2
3
1
4 5
4151011
Fig. 14 Bulb-and-Capillary-Tube Thermostat Components 1. Knob 2. Bezel 3. Body
4. Capillary tube 5. Bulb
7. See Figure 13. Disconnect the wires and remove the thermostat bulb (4). 8. Slide the sleeving off the old thermostat bulb and capillary tube. 9. Slide the sleeving onto the new thermostat bulb and capillary tube. 10. Connect the wires to the new thermostat body. 11. Secure the new thermostat and the bezel to the applicator base using the screws you removed earlier. 12. Push the knob onto the shaft. 13. Coat the new thermostat bulb with thermal joint compound.
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14. Insert the bulb into the groove on the bottom of the gun body as close to the gun modules as possible. 15. Bend the copper tube as needed to fit in the space provided. 16. Reinstall and secure the gun body thermostat bulb cover. 17. Reinstall and secure the tank enclosure. 18. Reinstall the pump cover. 19. Resume normal operation.
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TG09 Applicators
Replacing the Gun Body Heater
The gun body heater is housed in a bore in the gun body. WARNING: Disconnect equipment from line voltage. Failure to observe this warning could result in severe personal injury or death. 1. Turn off and lock out power to the applicator. 2. See Figure 15. Remove the gun body thermostat bulb cover (3). 3. Disconnect the heater wires at the wire nuts and remove the defective heater (2) from the bore in the gun body (1).
1
2 3 4151013A
Fig. 15 Replacing a Gun Body Heater 1. Gun body 2. Heater
3. Thermostat bulb cover
4. Coat the new heater with thermal joint compound. 5. Connect the new heater wires using the wire nuts and insert the heater into the bore in the gun body. 6. Reinstall the thermostat bulb cover on the gun body. 7. Resume normal operation.
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TG09 Applicators Replacing a Gun Module
Use this procedure to replace a defective gun module with a new gun module. WARNING: Risk of burns. Do not use the pattern controller to trigger the guns. Doing so can cause unexpected pressure buildup. 1. Relieve pressure in the gun body by manually activating one solenoid valve. WARNING: Disconnect equipment from line voltage. Failure to observe this warning could result in severe personal injury or death. 2. Turn off and lock out power to the applicator. CAUTION: Risk of equipment damage. Do not allow adhesive to be introduced into the air passages of a gun module. Adhesive can obstruct the air passages and damage the module. 3. See Figure 16. Remove the gun module from the gun body.
4151014
Fig. 16 Removing a Gun Module
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TG09 Applicators
Replacing a Gun Module (contd.)
4. Place a drain pan under the gun body. 5. Wipe off any hot melt material on the gun body, especially around the air passage(s). 6. Apply anti-seize compound to the two socket-head screws. 7. Secure the new gun module to the gun body using the two socket-head screws. Tighten to 3.4 Nm (30 in.-lb). 8. Restore the system to normal operation.
Replacing the Manifold Filter Screen
Use this procedure to replace the manifold filter screen. To clean the filter, refer to Cleaning the Manifold Filter in the Maintenance section. 1. Make sure the applicator is at operating temperature. 2. Turn off the operating air to the pump. WARNING: Risk of burns. Do not use the pattern controller to trigger the guns. Doing so can cause unexpected pressure buildup. 3. Relieve pressure in the gun body by manually activating one solenoid valve. WARNING: Risk of burns. Do not use a straight wrench when removing the filter. Use of a straight wrench can cause your hand to be positioned under the filter when the connection is broken, causing serious burns.
CAUTION: Risk of equipment damage. When unscrewing the filter assembly, be sure to leave the adapter installed in the manifold. Do not attempt to unscrew the adapter from the manifold. 4. See Figure 17. Unscrew the filter assembly and remove it from the manifold. NOTE: The steel filter adapter remains in the manifold.
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TG09 Applicators
4151005
Fig. 17 Removing the Filter Assembly
5. See Figure 18. Follow these steps to disassemble the filter. a. Remove the screw (5) from the bung (1). b. Slide the screen (4) off and discard it. c. Slide a new screen onto the core (3). d. Reassemble the filter.
4 3
ÎÎÎÎÎÎ ÎÎÎÎÎÎ ÎÎÎÎÎÎ ÎÎÎÎÎÎ ÎÎÎÎÎÎ
2 1 5
4151006
Fig. 18 Filter Components 1. Bung 2. O-ring 3. Core
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4. Screen 5. Screw
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TG09 Applicators
Replacing the Manifold Filter Screen (contd.)
6. Screw the filter assembly into the manifold until it is finger-tight only. CAUTION: Risk of equipment damage. Make sure the applicator is operating at operating temperature before tightening the filter. Cold material from the filter or manifold walls can cause the filter screen to collapse if it is tightened in a cold system. 7. Tighten the filter only until it seats. Do not over–tighten. 8. Set the pump air pressure at about 69 kPa (10 psi). 9. Place a drain pan under the manifold drain valve. 10. Open the manifold drain valve. 11. See Figure 19. Press, hold, and release the PUMP CYCLE push-button and allow adhesive to flow from the drain valve until it is clean and free of contaminants. 12. Close the drain valve. 13. Restore the pump air pressure to the normal setting.
4151004
Fig. 19 Draining Adhesive
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TG09 Applicators Replacing or Servicing the Piston Pump
45
Use these procedures to replace the piston pump or to replace the crossover tube O-ring and back-up ring, the check valve ball and seat, or the siphon ball assembly. You can use the parts list drawings as a guide as you perform the following procedures.
Pump Removal 1. Make sure the applicator is at operating temperature so the adhesive around the pump body is molten. 2. Turn off and lock out power to the applicator. 3. Turn off the operating air to the pump. 4. Remove the pump cover. 5. Disconnect the air line from the pump solenoid valve. 6. Disconnect the terminal block and housing from the solenoid valve by removing the terminal block screw. Be careful to save the gasket. NOTE: If you are replacing the pump with a new one, you will also need to disconnect the solenoid valve assembly from the pump. 7. Have a pan or rag ready to catch adhesive that will drip off the pump when it is removed. 8. See Figure 20. Remove the three bolts and washers (1) that secure the pump (2) to the tank and carefully lift the pump out of the tank.
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TG09 Applicators Pump Removal (contd.)
1
2
4151015A
Fig. 20 Removing the Pump 1. Bolts and washers
2. Pump
NOTE: If you are replacing the pump with a new one, go to Pump Installation.
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TG09 Applicators
47
Crossover Tube O-Ring and Back-Up Ring Replacement 1. See Figure 21. Remove the O-ring (5) and back-up ring (4) from the crossover tube (3). 2. Apply O-ring lubricant to the new O-ring. 3. Install a new O-ring and back-up ring on the crossover tube.
Check Valve Ball and Seat Replacement 1. See Figure 21. Remove the check valve ball (2) and ball seat (1) from the pump body. 2. Install a new check valve ball and ball seat. 1
Siphon Ball Cage and Seat Assembly Replacement 2 3
6
1. See Figure 21. Remove the siphon ball seat (8), siphon ball (7), and siphon ball cage (6) from the bottom of the pump body. 2. Install a new siphon ball seat, siphon ball, and siphon ball cage.
4
7
5 8
4151016A
Fig. 21 Pump Components 1. 2. 3. 4. 5. 6. 7. 8.
Check valve Check valve ball Crossover tube Back-up ring O-ring Siphon ball cage Siphon ball Siphon ball seat
2000 Nordson Corporation All rights reserved
237 507D Issued 11/00
41-TG09-MA-02
48
TG09 Applicators Pump Installation 1. Carefully lower the pump into the tank, allowing it to rest on or near the tank cover. CAUTION: Risk of equipment damage. Do not force the pump crossover tube into the manifold. Doing so will damage the O-ring. 2. Unless the tank is completely empty, heat the adhesive in the tank until the pump crossover tube will easily slide into the hole in the manifold. 3. Reinstall the three bolts that secure the pump to the tank. 4. Reinstall the terminal block on the solenoid valve, including the gasket, if applicable. NOTE: If you installed a new pump, you will need to install the solenoid valve on the new pump. 5. Reconnect the air line to the pump solenoid valve. 6. Reinstall the pump cover.
System Restoration 1. Restore the operating air to the pump and guns to the normal settings. 2. Restore electrical power to the system. 3. Turn the temperature control knobs to the normal operating temperature setpoints. 4. Fill the tank with adhesive to within 25 mm (1 in.) of the top of the tank.
41-TG09-MA-02
237 507D Issued 11/00
2000 Nordson Corporation All rights reserved
TG09 Applicators Replacing the Gun Body
49
Use these procedures to replace the gun body.
Gun Body Removal 1. Heat the applicator enough to cause adhesive to begin melting. This will ensure that adhesive does not prevent the gun body from being separated from the manifold. 2. Relieve pressure in the gun body by manually activating one solenoid valve. WARNING: Disconnect equipment from line voltage. Failure to observe this warning could result in severe personal injury or death. 3. Disconnect and lock out power to the applicator. 4. Turn off the operating air to the pump and guns. 5. Remove the pump cover. 6. See Figure 22. Remove the screws (1) that secure the tank enclosure (2) in place, but do not remove the tank enclosure.
1
2
4151026A
Fig. 22 Removing the Tank Enclosure Screws 1. Screw
2000 Nordson Corporation All rights reserved
237 507D Issued 11/00
2. Tank enclosure
41-TG09-MA-02
50
TG09 Applicators Gun Body Removal (contd.) 7. See Figure 23. Remove the gun air manifold (1) and gasket from the gun body (2) and lay the manifold aside, with the solenoid valves and air line still attached. 8. Remove the screws that secure the gun body access cover (9) to the applicator base and remove the cover. 9. Remove the screws that secure the thermostat bulb cover (6) to the gun body and remove the cover from the gun body, allowing the thermostat bulb (5) to hang free. 10. Slide the heater (4) out of the gun body and allow it to hang free. NOTE: Nordson Corporation recommends replacing the heater any time you replace the gun body. 11. Have a pan or rag ready to catch adhesive that will drain from the manifold when the gun body is removed. When the pump is installed and not energized, the material in the tank will not drain. 12. Remove the six bolts (8) that secure the gun body to the manifold. 13. Lift the tank enclosure slightly and remove the gun body. 14. Examine the O-ring (7) and replace it if necessary. 15. Remove the screws that secure the gun modules (3) to the gun body and remove the modules.
41-TG09-MA-02
237 507D Issued 11/00
2000 Nordson Corporation All rights reserved
TG09 Applicators
51
7
2
8 9
4 5
1 3
6
4151017A
Fig. 23 Removing the Gun Body 1. Air manifold with attached solenoid valve 2. Gun body 3. Gun modules
2000 Nordson Corporation All rights reserved
4. Heater 5. Thermostat bulb and capillary tube 6. Thermostat bulb cover
237 507D Issued 11/00
7. Manifold O-ring 8. Bolts 9. Gun body access cover
41-TG09-MA-02
52
TG09 Applicators Gun Body Installation 1. See Figure 23. Install the gun modules (3) on the new gun body (2). Apply anti-seize compound to the module socket-head screws. 2. Make sure the manifold O-ring (7) is in place and that the gun body mounting surface is clean. 3. Lift the tank enclosure slightly and position the gun body against the manifold. Secure the gun body with the six bolts (8). 4. Coat the heater (4) with thermal joint compound and insert it into the bore in the gun body (2). 5. Coat the thermostat bulb (5) with thermal joint compound and insert it into the groove in the bottom of the gun body (2). 6. Hold the thermostat capillary tube, bulb, and heater wires in place while carefully installing the thermostat bulb cover (6) on the gun body. Secure the bulb cover with the screws. NOTE: The screw on the bottom of the gun body acts as a stop to keep the heater from sliding back too far. Make sure the heater is not obstructing the hole for this screw. 7. Reinstall the gun body access cover (9) on the applicator base. 8. Reinstall the screws that secure the tank enclosure to the applicator. 9. Reinstall the gun air manifold and gasket (1) on the gun body. 10. Reinstall the pump cover.
System Restoration 1. Restore the operating air to the pump and guns to the normal settings. 2. Restore electrical power to the system. 3. Turn the temperature control knobs to the normal operating temperature setpoints. 4. Fill the tank with adhesive to within 25 mm (1 in.) of the top of the tank.
41-TG09-MA-02
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2000 Nordson Corporation All rights reserved
53
TG09 Applicators
To order parts, call the Nordson Customer Service Center or contact your Nordson representative. Use the parts lists and accompanying illustrations in this section to locate and describe parts correctly.
7. Parts
Using the Illustrated Parts Lists
Numbers in the Item column correspond to numbers that identify parts in illustrations following each parts list. The code NS (not shown) indicates that a listed part is not illustrated. A dash (—) is used when the part number applies to all parts in the illustration. The six-digit number in the Part column is the Nordson Corporation part number. A series of dashes in this column (- - - - - -) means the part cannot be ordered separately. The Description column gives the part name, as well as its dimensions and other characteristics when appropriate. Indentions show the relationships between assemblies, subassemblies, and parts.
Part
Item
Description
Quantity
—
000 000
Assembly
1
1
000 000
Subassembly
2
2
000 000
Part
1
Note A
If you order the assembly, items 1 and 2 will be included. If you order item 1, item 2 will be included. If you order item 2, you will receive item 2 only. The number in the Quantity column is the quantity required per unit, assembly, or subassembly. The code AR (As Required) is used if the part number is a bulk item ordered in quantities or if the quantity per assembly depends on the product version or model. Letters in the Note column refer to notes at the end of each parts list. Notes contain important information about usage and ordering. Special attention should be given to notes.
2000 Nordson Corporation All rights reserved
237 507D Issued 11/00
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54
TG09 Applicators
Recommended Spare Parts and Supplies
Nordson Corporation recommends that you keep the following spare parts and supplies available for use during maintenance and repair activities. Description
Part
Quantity
Note
308 955
Pump assembly, 10:1 single-acting, with solenoid valve
1
138 177
Service kit, pump siphon ball, cage, seat
1
274 581
Service kit, filter bung (manifold filter)
1
274 578
Manifold filter screen, 0.006 mesh, 5.38 in.
1
941 172
Manifold filter O-ring, Viton, 0.813 x 1.0 x 0.094 in.
1
156 274
Over-temperature thermostat, close-on-rise, 450 F
1
308 954
Capillary-tube-and-bulb thermostat
1
109 327
Gun body heater, 0.38 in. diameter, 240 W, 240 Vac, 4.125 in. long
1
A
109 881
Gun body heater, 0.38 in. diameter, 500 W, 240 Vac, 7.04 in. long
1
B
303 010
Solenoid valve, 24 Vdc, 1/4 NPT, quick-disconnect, piloted (for guns)
1
901 155
Solenoid valve, 24 Vdc, 1/4 NPT, quick-disconnect, direct (for pump)
1
222 495
H-200 right-angle gun module
1
940 111
H-200 gun module O-ring, Viton, 0.301 x 0.070 in.
2
901 915
Nozzle cleaning kit
1
331 871
Nut driver, 5/32 (to remove right-angle nozzles)
1
900 223
High-temperature lubricant, 4-oz tube
1
900 344
Anti-seize compound, 8-oz can
1
275 386
Thermal joint compound, 2-oz tube
1
NOTE A: Use this heater for applicators with 2 modules/2 blanks or 4 modules. B: Use this heater for applicators with 6 modules or 4 modules/2 blanks.
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55
TG09 Applicators TG09 Applicators and Installation Kits
Instructions for installing TG09 applicator systems are provided with the TG09 applicator and associated installation kits. The following applicators and installation kits are available. Description
Part
Note
328 452
TG09 applicator, 2 modules/2 blanks
A
328 445
TG09 applicator, 4 modules
B
328 461
TG09 applicator, 6 modules
C
331 864
TG09 applicator, 4 modules/2 blanks
D
328 446
Installation kit, brackets, TG09 applicators
E
328 447
Installation kit, air system, TG09 applicators
F
328 453
Installation kit, air manifold/solenoid valve, 4-module gun body, two-ported air
G
328 449
Installation kit, air manifold/solenoid valve, 4-module gun body, common air
G
328 464
Installation kit, air manifold/solenoid valve, 6-module gun body
H
156 856
Installation kit, product sensor, diffuse-reflective, SWF
I
149 541
Installation kit, product sensor, retro-reflective, SWF
I
156 858
Pattern controller, PC-40, PS-40 (option 1)
J
156 859
Pattern controller, PC-44, PS-40 (option 2)
K
149 275
Installation kit, encoder (order when installing option 2, part 156 859)
149 539
Gear, matt feed roller shaft, 1.75 in. (order when installing option 2, part 156 859)
L
149 540
Gear, matt feed roller shaft, 1.50 in. (order when installing option 2, part 156 859)
L
NOTE A: B: C: D: E: F: G: H: I: J: K: L:
This applicator comes with two gun modules and two blank modules installed on a 4-module gun body. This applicator comes with four gun modules installed on a 4-module gun body. This applicator comes with six gun modules installed on a 6-module gun body. This applicator comes with four gun modules and two blank modules installed on a 6-module gun body. This kit contains brackets suitable for installing TG09 applicators on an SWF Traymatic/Blissmatic machine. This kit contains nylon tubing, air regulators, and gauges for the pump and gun solenoid valves. This kit contains a gun air manifold and solenoid valves and can be used only with parts 328 452 or 328 445. This kit contains a gun air manifold and solenoid valves and can be used only with parts 328 461 or 331 864. Order one of these two kits (156 856 or 149 541). Both kits contain a product sensor suitable for installation on an SWF Traymatic/Blissmatic machine. This kit includes all the parts necessary to install a timer on an SWF Blissmatic/Traymatic machine. To install a pattern controller and an encoder, refer to part 156 859. To install this kit you must also order part 149 275 (an encoder) and either part 149 539 or 149 540 (a matt feed roller shaft gear). Order the gear size that matches the diameter of the matt feed roller shaft on your unit.
2000 Nordson Corporation All rights reserved
237 507D Issued 11/00
41-TG09-MA-02
56
TG09 Applicators
TG09 Applicator Parts Lists
The TG09 applicator is available in both a left- and right-hand configuration. This section contains a parts list for the common module (the part of the applicator that is the same for both configurations) and a parts list for the left- and right-hand configurations of the applicator.
Common Module See Figure 24. Item
Part
—
230 089
Module, common, TG09
—
1
230 082
Cover, pump
1
2
983 404
Washer, lock, M, split, M8
11
3
983 414
Washer, flat, M, narrow, M8
11
4
308 955
Pump assembly, single-acting, w/solenoid valve
1
5
982 212
Screw, hex-head, cap, M8 x 30 mm
5
6
902 518
Stud, ball
2
7
982 336
Screw, flat-head, recessed, M5 x 20 mm
6
8
230 077
Enclosure, tank
1
9
982 000
Screw, pan-head, slotted, M5 x 10 mm
1
10
982 293
Screw, cross-recessed, pan-head, 10-32 x 0.5 in.
12
11
983 035
Washer, flat, M5
7
12
109 904
Gasket, tank
1
13
230 081
Cover, tank
1
14
------
Tank
1
15
308 954
Thermostat, 200–400 °F, bulb-and-capillary tube
2
16
230 079
Clamp, bulb-and-capillary-tube thermostat
1
17
983 064
Washer, flat, E, 0.156 x 0.375 x 0.049 in.
2
18
983 400
Washer, lock, M, split, M3
8
19
983 403
Washer, lock, M, split, M4
2
20
982 080
Screw, pan-head, M3 x 10 mm
6
21
982 092
Screw, pan-head, slotted, M4 x 10 mm
2
22
982 270
Screw, pan-head, slotted, M3 x 5 mm
2
23
------
Thermostat, w/insulator, 450 F
1
Description
Quantity
Note
A
B
B
NOTE A: Refer to Piston Pump Parts List. B: Apply thermal joint compound, part 275 386. For a replacement thermostat, order part 156 274. Continued on next page
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57
TG09 Applicators
Item
Part
24
288 154
Spacer, manifold, 0.500 ID x 0.546 in.
2
25
288 023
Screw, split, hex-head, M8-1.25
5
26
328 450
Push-button, manual, PUMP CYCLE
1
27
230 076
Frame (base)
1
28
274 585
Circuit breaker, 3-pole, 30 A
1
29
981 055
Screw, pan-head, 8-32 x 0.250 in.
5
30
983 010
Washer, flat, E, 0.188 x 0.375 x 0.040 in.
4
31
982 107
Screw, hex-head, cap, M8 x 70 mm
1
32
981 054
Screw, pan-head, 8-32 x 0.750 in., slotted
4
33
982 249
Screw, pan-head, recessed, M3 x 6 mm
4
34
939 650
Lamp, indicator, rectangular, green, 230 Vac
1
35
981 427
Screw, pan-head, 6-32 x 0.250 in.
4
36
939 229
Lamp, indicator, rectangular, amber, 250 Vac
2
37
308 949
Label, controls, TG09
1
38
984 111
Nut, hex, 8-32
4
39
983 111
Washer, lock, E, split, 8
5
40
933 057
Block, terminal, 8-station, 300 Vac maximum
1
41
------
Filter bung assembly
1
C, D, E
42
274 569
Adapter, filter bung
1
F
43
941 220
O-ring, Viton, 1.125 x 1.313 x 0.094 in.
1
C
44
276 024
Valve assembly, drain
1
C, D
45
230 074
Manifold, common
1
46
940 281
O-ring, Viton, 1.375 x 10.500 x 0.063 in.
2
47
288 148
Spacer, tank, 0.50 ID x 2.04 in.
1
48
230 083
Isolator
1
49
982 255
Screw, Chez-head, slotted, M6 x 50 mm
2
50
901 576
Handle, plastic
1
51
230 084
Lid, applicator
1
NOTE C: D: E: F:
Description
Quantity
Note
C
Apply O-ring lubricant, part 900 223. Apply anti-seize lubricant, part 900 344. Refer to Manifold Filter Parts List. Apply retaining cylindrical adhesive, part 900 419. Continued on next page
2000 Nordson Corporation All rights reserved
237 507D Issued 11/00
41-TG09-MA-02
58
TG09 Applicators Common Module (contd.) Item
Part
Description
Quantity
52
982 320
Screw, pan-head, recessed, M5 x 16 mm
2
53
983 551
Washer, 0.250 ID x 0.50 OD x 0.060 in.
2
54
106 433
Spacer, 0.218 in. ID, 0.375 in. OD
2
55
983 409
Washer, lock, M, split, M6
2
56
984 703
Nut, hex, M6
2
57
230 085
Lid, inner
1
58
230 078
Panel, access, electrical
1
59
------
Rivet, blind, 1/8 x 0.187 in.
4
60
902 522
Retainer, stud, 0.028 in.
2
61
983 100
Washer, lock, E, internal, 6
2
62
981 039
Screw, pan-head, 6-32 x 0.312 in., slotted
2
63
331 857
Knob, thermostat, bulb-and-capillary tube
1
64
331 858
Bezel, thermostat, bulb-and-capillary tube
1
NS
308 950
Insulation, tank
1
NS
933 756
Jumper, terminal block, low-profile, 9/16 in.
6
NS
931 210
Sleeving, insulation, 0.312 in. ID
7
NS
276 578
Cover, circuit breaker
1
Note
NS: Not Shown
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2000 Nordson Corporation All rights reserved
59
TG09 Applicators
6
5
1
7 2, 3
8
4
9 10 48
49
11 12, 13
50 52 53
14
51 54
46
55
15
47
45
23
42, 43
57
20 58
36
37
21
21
2, 3 24
19
25
35
26
10 30
34
59
60
6
59
18 20
22
38 39 40
41
18
17
19
44
56
16
26
64
63
33
28 2, 3
32 31
61, 62
27
15, 29
5
4151018A
Fig. 24 Applicator Common Module Parts
2000 Nordson Corporation All rights reserved
237 507D Issued 11/00
41-TG09-MA-02
60
TG09 Applicators Right-Hand and Left-Hand Applicators See Figure 25. Item
Part
Description
Quantity
Note
—
230 091
Applicator, right, TG09
—
—
230 092
Applicator, left, TG09
—
1
973 543
Plug, O-ring, straight-thread, 7/16-20
2
2
227 037
Tag, warning, hydraulic pressure
1
3
146 007
Tag, caution, surface temperature
2
4
230 089
Module, common, TG09
1
5
308 951
Box, junction
1
6
308 952
Cover, junction box
2
7
940 161
O-ring, Viton, 0.614 ID x 0.070 in.
1
8
230 080
Body, gun, right, 4-module
1
NS
230 075
Body, gun, left, 4-module
1
NS
331 859
Body, gun, right, 6-module
1
NS
331 860
Body, gun, left, 6-module
1
9
222 495
Gun module, H-200, right angle
4
10
983 111
Washer, lock, E, split, 8
3
11
983 010
Washer, flat, E, 0.188 x 0.375 x 0.040 in.
3
12
981 064
Screw, pan-head, 8-32 x 0.375 in., slotted
3
13
308 944
Cover, bulb, thermostat, 4-module gun body
1
NS
331 861
Cover, bulb, thermostat, 6-module gun body
1
14
973 592
Plug, O-ring, straight-thread, 1/2-20
1
15
983 140
Washer, lock, E, split, 1/4 in., steel
6
16
981 222
Screw, hex-head, 1/4-20 x 1.50 in., cap
6
17
109 327
Heater, 0.38 x 4.13 in. long, 300 W, 240 Vac
1
C, D
NS
109 881
Heater, 0.38 x 7.04 in. long, 500 W, 240 Vac
1
C, E
18
308 953
Cover, gun access
1
A
A
B
A
NOTE A: Apply O-ring lubricant, part 900 223. B: Apply anti-seize lubricant, part 900 344. C: Apply thermal joint compound, part 275 386. D: Use this heater on applicators with a 4-module gun body. E: Use this heater on applicators with a 6-module gun body. NS: Not Shown Continued on next page
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61
TG09 Applicators
Item
Part
Description
Quantity
19
982 923
Screw, cross-recessed, pan-head, 10-32 x 0.5 in.
6
NS
933 056
Connector, plastic, 2-station
1
NS
939 320
Connector, plastic, 3-station
1
NS
116 176
Decal, shock warning
1
Note
NS: Not Shown
1
2
5 3 1
4
6
15 7 16
14
8
17
19
18
9 13
10, 11 12 4151019
Fig. 25 Right-Hand Applicator Parts
2000 Nordson Corporation All rights reserved
237 507D Issued 11/00
41-TG09-MA-02
62
TG09 Applicators
Piston Pump Parts List Item
See Figure 26 for items 1–20.
Part
Description
Quantity
Note
—
308 955
Pump assembly, single-acting, w/solenoid valve
—
A
1
982 147
Screw, hex-head, cap, M6 x 120 mm
4
B
2
983 409
Washer, lock, M, split, M6
5
3
101 358
Cap, air cylinder, single-acting
1
4
102 317
Bumper, piston stop
1
5
940 440
O-ring, Viton, 3.750 x 3.875 x 0.063 in.
1
6
288 118
Cylinder, air, high-volume
1
7
984 703
Nut, hex, M6
1
8
102 318
Stop, pump, piston
1
9
288 115
Washer, piston, cup, high-volume
1
10
288 116
Cup, piston, high-volume
1
11
288 117
Washer, piston, seal, high-volume
1
12
973 121
Elbow, male, pipe, hydraulic, 1/8 in.
1
D
1
D
1/ 8
1/ 4
13
973 168
Ell, pipe, reducing, street,
14
901 155
Valve, solenoid, 24 Vdc, 1/4 NPT
1
15
971 179
Elbow, male, 3/8 in. tube x 1/4 NPT
1
16
986 200
Retaining ring, external, 112, basic
1
17
983 533
Washer, flat, E, spring-guide
1
18
102 321
Support, spring guide
1
19
102 319
Spring, compression, 11.33 x 1.50 x 0.162 in.
1
20
288 119
Adapter, air cylinder, high volume
1
NOTE A: B: C: D:
x
in.
C B
D
For a complete pump, order this part number. Apply anti-seize compound, part 900 344. Apply high-temperature lubricant, part 900 223. Apply PTFE paste, part 900 236.
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2000 Nordson Corporation All rights reserved
63
TG09 Applicators
1 2
3 16 17
12
4
18
5 6
A B
19
7 2 8
13 9 10
14
11
15
20
4151020
Fig. 26 Piston Pump Parts (1 of 2)
2000 Nordson Corporation All rights reserved
237 507D Issued 11/00
41-TG09-MA-02
64
TG09 Applicators
Piston Pump Parts List (contd.) Item
See Figure 27 for items 21–43.
Part
Description
Quantity
21
102 323
Retainer, spring
1
22
984 545
Nut, lock, bearing, PN-08
1
23
983 184
Washer, lock, E, bearing, PN-08
1
24
102 324
Seat, ball, check valve
1
25
900 000
Ball, 440 stainless steel, 0.375 in.
1
26
102 325
Mount, pump, machined, 10:1
1
27
986 603
Retaining ring, internal, 81, basic
1
28
273 138
Washer, 0.799 OD x 0.543 ID x 0.340 in. thick
1
29
273 139
Seal, pump
1
30
102 326
Body, pump, single-acting
1
31
288 031
Tube, crossover
Note
1 7/ 16
9/ 16
32
954 013
Back-up ring, single,
33
940 133
O-ring, Viton, 0.426 ID x 0.700 in. width
1
34
985 309
Pin, groove, type-A, 0.125 x 1.0 in.
1
35
102 322
Rod, pump, single-acting
1
36
940 121
O-ring, Viton, 0.364 ID x 0.700 in.
1
37
134 166
Plug, piston, single-acting
1
38
940 157
O-ring, Viton, black, 0.562 ID x 0.688 in.
1
39
102 327
Piston, pump, single-acting, hydraulic
1
40
102 329
Screw, shoulder,1/4-20 x 0.312 in. OD
1
41
240 533
Cage, ball, siphon
1
42
900 023
Ball, 440, stainless steel, 0.750 in.
1
43
240 534
Seat, siphon ball
1
x
in.
1
A A B
NOTE A: Apply high-temperature lubricant, part 900 223. B: Apply retaining cylindrical adhesive, part 900 419.
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2000 Nordson Corporation All rights reserved
TG09 Applicators
65
26
A B 21
35
22 27
23
36
28
37
29
38 39
30 31
40 41
24
32 33
25
42 43
34 4151021
Fig. 27 Piston Pump Parts (2 of 2)
2000 Nordson Corporation All rights reserved
237 507D Issued 11/00
41-TG09-MA-02
66
TG09 Applicators
Manifold Filter Parts List Item
See Figure 28. The manifold filter screws into an adapter in the manifold. Refer to Common Module for the adapter part number.
Part
Description
Quantity
—
274 581
Service kit, filter bung assembly
—
1
274 578
Screen, filter, 0.006 mesh, 5.38 in.
1
2
981 747
Screw, round-head, 10-32 x 6.25 in., slotted
1
3
274 513
Bung, filter
1
4
941 172
O-ring, Viton, 0.813 x 1.000 x 0.094 in.
1
5
274 579
Core, filter, 5.718 in. long
1
1
5
Note
ÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ
4 3 2
4130043
Fig. 28 Manifold Filter Parts
41-TG09-MA-02
237 507D Issued 11/00
2000 Nordson Corporation All rights reserved
67
TG09 Applicators Gun Module and Nozzle Parts Lists
The gun modules used on TG09 applicators are right-angle integrated gun modules. The gun module includes the module, a nozzle adapter, and a nozzle. Use the following parts lists to order replacement gun modules or different sizes of nozzles for your gun modules.
Gun Module See Figure 29. Contact the Nordson Customer Service Center for information on gun modules available through the Rebuild/Exchange (RBX) program. Item
Part
Description
Quantity
1
940 111
O-ring, Viton, 0.301 x 0.070 in.
2
2
222 495
Service kit, gun module, H-200, right-angle
1
Note A
NOTE A: This kit includes two O-rings and two screws (to attach the gun module to the gun manifold).
2
1
4151022
Fig. 29 Right-Angle Gun Module Parts
2000 Nordson Corporation All rights reserved
237 507D Issued 11/00
41-TG09-MA-02
68
TG09 Applicators Nozzles See Figure 30. Tables 2 and 3 list the nozzles that can be used with H-200 right-angle gun modules. Nordson Corporation recommends using stainless-steel nozzles. Table 2 Single-Orifice Nozzles, Stainless-Steel, with Insert
Engagement mm (in.)
Orifice Diameter mm (in.) 0.20 (0.008)
0.25 (0.010
0.31 (0.012)
0.36 (0.014)
0.41 (0.016)
0.46 (0.018)
0.51 (0.020)
236 208
236 210
236 212
236 214
236 216
236 218
236 220
236 621
236 312
236 314
236 316
236 318
236 320
2.5 (0.100)
236 412
236 414
236 416
236 418
236 420
3.8 (0.150)
236 612
236 614
236 616
236 618
236 620
1.3 (0.050) 1.9 (0.075)
Table 3 Single-Orifice Nozzles, Brass, One-Piece Engagement mm (in.) 7.6 (t0.300)
Orifice Diameter mm (in.) 0.41 (0.016)
0.46 (0.018)
0.53 (0.021)
0.61 (0.024)
0.71 (0.028)
236 008
236 018
236 027
236 040
236 060
1
2 4151023A
Fig. 30 Nozzle and Nozzle Adapter 1. Nozzle
41-TG09-MA-02
2. Nozzle adapter (with nozzle installed)
237 507D Issued 11/00
2000 Nordson Corporation All rights reserved
69
TG09 Applicators Solenoid Valve Parts List
Item
Part
See Figure 31. Nordson Corporation recommends the following solenoid valves for your TG09 applicator pumps and guns. A solenoid valve can be damaged if its voltage rating does not match the input voltage from the triggering device. Make sure the ratings match. Additionally, make sure that the solenoid valve meets high-temperature specifications. The following solenoid valves are suitable for use at service temperatures above 85C (185 F). Description
Quantity
Note
NS
901 155
Solenoid valve, 0.5 Cv, 24 Vdc, 1/4 NPT, quick-disconnect, direct
1
A
1
303 010
Solenoid valve, 0.88 Cv, 24 Vdc, 1/4 NPT, quick-disconnect, w/light (LED), piloted
1
B
—
231 260
Installation kit, solenoid valve
—
C
2
973 402
Pipe plug, 1/8 NPT
1
3
231 266
Silencer, air, 1/8 NPT
1
4
973 372
Bushing, pipe, hydraulic, 1/4 NPT x 1/8 NPT
1
5
973 411
Pipe plug, 1/4 NPT
1
NOTE A: Order this part to replace a pump solenoid valve. B: Order this part to replace a gun solenoid valve. This valve must be installed as shown in Figure 31. Order the installation kit, part 231 260, separately. C: Use this installation kit when installing solenoid valve part 303 010. NS: Not Shown
1
2 3
5
4
4601139
Fig. 31 Solenoid Valve Parts
2000 Nordson Corporation All rights reserved
237 507D Issued 11/00
41-TG09-MA-02
70
TG09 Applicators
8. Wiring Diagrams
The following wiring diagrams are provided for reference as needed.
PUMP CYCLE PUSHBUTTON
WHITE
2 (–) WHITE TO 1 (+) BLACK PUMP SOLENOID VALVE RED
BLACK
1
UNSWITCHED +24 Vdc
2
COMMON
3
SWITCHED (SIGNAL) +24 Vdc
RED 4151028
Fig. 32 TG09 Applicator Terminal Block Connections to a Switched Positive (PC40) Controller
1
UNSWITCHED COMMON
EPC 30 CONTROLLER x7 ( Terminal 13 ) 24V Common
2
+24 Vdc
x7
( Terminals 1–3–5–7 )
3
SWITCHED COMMON
x7
( Terminals 2–4–6–8 )
PUMP CYCLE PUSHBUTTON
2 (–) WHITE 1 (+) BLACK TO PUMP SOLENOID RED VALVE
WHITE BLACK RED
4151034A
Fig. 33 TG09 Applicator Terminal Block Connections to a Switched Negative( EPC30) Controller
41-TG09-MA-02
237 507D Issued 11/00
2000 Nordson Corporation All rights reserved
71
TG09 Applicators
Wiring Diagrams (contd) NOTE: The numbers shown in Figure 34 Terminal are wire numbers, some of which are used more than once.
OVER–TEMPERATURE THERMOSTAT
240 Vac SINGLE PHASE 50/60 hz
L1
5 CIRCUIT
3
3 GREEN LIGHT
L2
GROUND
5
BREAKER
3
3
AUX TRIP
3
TEMPERATURE CONTROLLER
6
AMBER LIGHT
2 2
TANK HEATER
2
2800 WATTS
1
AMBER LIGHT TEMPERATURE CONTROLLER
2 4
GUN HEATER
3
300 WATTS
4151027A
Fig. 34 TG09 Applicator System Wiring Diagram
2000 Nordson Corporation All rights reserved
237 507D Issued 11/00
41-TG09-MA-02
72
TG09 Applicators
41-TG09-MA-02
237 507D Issued 11/00
2000 Nordson Corporation All rights reserved
