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Dymax SG-200 High-Flow Spray Gun System User Guide

Troubleshooting

Table 2. Troubleshooting for the SG-200 Spray Gun

Problem

Possible Cause

Corrective Action

Spray valve does not cycle

Air pressure to air section too low

Increase air pressure to 60-100 psi

Packing nut is too tight

Loosen packing nut until valve just begins
to cycle, retighten

Stroke adjuster is bottomed out

Back out stroke adjuster by turning it
counter-clockwise

Material is cured in the valve

Disassemble and clean valve

Valve was assembled without
lubricating the o-ring seals

Disassemble valve, lubricate seals,
and re-assemble

Material leaks from valve tip

Needle and/or seat are worn

Replace parts as necessary

Seat is not tightened enough against
fluid section

Use seat wrench to tighten seat onto fluid
section

Valve leaks from mid-section

Packing nut is loose

Tighten packing nut until snug

Packing is worn

Replace packing

Valve does not spray anything

Fluid pressure is too low

Increase fluid pressure

Atomization pressure too high
impeding material flow

Reduce atomizing pressure, increase nozzle
size

Material cured in fluid section

Disassemble valve and clean

Spray rate too fast

Material PSI too high

Reduce material pressure

Spray rate too slow

Material PSI/flow rate too low

Increase material pressure. Increase nozzle
size

Air bubbles in fluid

Valve not properly purged

Flip valve upside down and cycle until air
bubbles are removed

Problem with fluid delivery system

Diagnose and repair

Not enough material flow

Nozzle bore too small

Atomizing air pressure set too high

Reduce atomizing air pressure

Poor spray pattern

Cured material at tip of needle and
seat

Remove air cap and clean tip

Cured material in air cap

Remove air cap and clean

Incorrect atomizing air pressure

Adjust atomizing air pressure

Damaged needle and or seat

Replace parts as necessary

Содержание SG-200

Страница 1: ...y Gun System with Remote Timer Low Viscosity Systems 5 000 cP with cartridge reservoirs Low Viscosity Systems 5 000 cP with bottle reservoirs Low Viscosity Systems 5 000 cP with pail reservoirs High Viscosity Systems 5 000 80 000 cP with ram pump ...

Страница 2: ... line of fluid dispensing and UV light curing systems Dispensing systems include manual and automatic fluid dispensing systems designed for compatibility and high performance with Dymax adhesives Light curing systems include UV visible LED light curing spot lamps flood lamps and conveyor systems Dymax adhesives and curing systems optimize the speed of automated assembly allowing for 100 in line in...

Страница 3: ... Utilities Required 14 Choosing and Installing an Alternative Pressure Gauge 14 Initial Setup of the Spray Gun 15 Connecting the Air Filter Regulator 15 Connecting the DVC 345 Controller 16 Connecting the Material Reservoir 17 Optimizing Spray System 24 Adjust the Flow Rate Spray of the Dispensing System 24 Starting Using and Stopping the Dispensing System 25 Starting and Using the System 25 Shutt...

Страница 4: ... Where to Get Help Additional resources are available to ensure a trouble free experience with our products Detailed product information on www dymax com Customer Support and Application Engineering teams are available in the United States Monday through Friday from 8 00 a m to 5 30 p m Eastern Standard Time You can also email Dymax at info dymax com Please see the back cover for worldwide contact...

Страница 5: ...nd Explosion Hazard for Spraying Applications WARNINGS Ground all equipment in the work area Improper grounding poor ventilation open flames or sparks can cause hazardous conditions and result in a fire explosion or other serious injury If static sparking occurs or an electric shock is felt while using the equipment stop spraying immediately Do not use the equipment until you identify and correct ...

Страница 6: ...rs Pail reservoir tanks manufactured from stainless steel Compatible with a greater number of fluids Air filter regulator shutoff valve depressurizes system when shutoff valve is closed Provides a safer system for users High quality air precision regulator supplied with three pressure gauges with different pressure ranges Ability to select the appropriate gauge for accurate measurement and control...

Страница 7: ...e and out of the tank for dispensing c Positive Displacement Ram Pail Pumps Ram pumps are ideal delivery systems for dispensing high volume and or high viscosity materials Utilizing a check valve positive displacement ram style head and a downstream regulator this system provides steady even flow of material Dymax s are designed for use with 5 gal straight and or tapered pails Fluid Line The fluid...

Страница 8: ... 20 oz Fluid Reservoir Material Reservoir Cartridge Reservoir Retainer Shown Holds Cartridge Reservoir Inside Air Filter Regulator Fluid Line Plant Compressed Air In nptf DVC 345 Controller Handheld Spray Gun Atomizing Air Regulator Spray Gun Stand Compressed Air Line Material Pressure Regulator Regulator Stand ...

Страница 9: ...viscosity material over large areas Retainer tanks and ram pump configurations and process connection points are shown in Figure 2 Figure 3 Figure 4 Figure 5 Cartridge Reservoir Retainers Cartridge reservoir retainers are supplied in two sizes but the design features of each are similar Figure 2 Each cartridge reservoir retainer includes one empty reusable cartridge reservoir that can be filled wi...

Страница 10: ...nk is pressurized the fluid is pushed up the dip tube and into the fluid dispensing line Figure 3 The air precision regulator is permanently attached to the cover of the tank Figure 3 Retainer for Bottle Drop In Reservoir Air Precision Regulator Adhesive Outlet Port and Push Through Fitting Bottle Reservoir Tank Tank Cover Cover Hold Down Knob Compressed Air In From Filter Regulator Fluid Out Pres...

Страница 11: ... tube and into the fluid dispensing line The tank cover includes a permanently mounted compressed air filter and shutoff valve The cover also includes a permanently attached air precision regulator and safety pressure relief valve Figure 4 Figure 4 Pail Reservoir Tank Components Pail reservoir includes a plastic liner You can place your pail reservoir inside your plastic liner if desired Liners ar...

Страница 12: ...ross a range of input pressures Also included in the high pressure configuration is a length of stainless braided hose with compression swivels and fittings to maximize throughput while extending flexibility to the operator As a system the SG 200 and ram pump system provide a solution for high flow high viscosity delivery beyond the capabilities of standard pneumatic reservoirs Figure 5 Ram Pump S...

Страница 13: ...ay gun with controlling air regulators DVC 345 timed shot controller Spray gun stand Air filter regulator Air line kit length of blue 1 4 in 6 3 mm OD tubing with fitting on one end Air line kit length of blue 1 4 in 6 3 mm OD tubing Fluid line kit length of black 3 8 in 9 5 mm OD tubing Fluid line kit adapter 3 8 in 9 5 mm x 3 8 in MNPT comp One cartridge reservoir retainer 12 oz 300 mL or 20 oz ...

Страница 14: ...ulator mounted on pail reservoir retainer that includes three pressure gauges 0 30 psi 0 2 bar for very low to medium viscosity materials 0 60 psi 0 4 1 bar for medium viscosity materials 0 100 psi 0 6 9 bar for high viscosity materials 5 Gal positive displacement ram pump with flow control downstream regulator 1 200 psi max input Incoming air filter with dump Incoming shutoff valve Fluid line kit...

Страница 15: ...r Filter Regulator 1 Check to make sure the dual tubes from the atomizing head on the front of the SG 200 valve is connected to the dual port of the atomizing control regulator The air line between the atomizing control regulator and material pressure regulator should also be pre configured Figure 6 2 Securely mount the air filter regulator in an upright position filter bowl at the bottom in accor...

Страница 16: ...s to Port B Figure 7 4 Connect the jack from the spray gun to the External Trigger Jack located on the back of the 345 controller 5 Connect the DVC 345 Controller Air In Port on the rear panel to the control valves Figure 7 DVC 345 Connections 6 Turn the Controller to untimed mode for manual use For timed shot applications program the controller appropriately Instructions can be found in MAN028 DV...

Страница 17: ... Unscrew and remove the plug from the cartridge reservoir outlet Screw in the supplied 3 8 in 9 5 mm fitting into the reservoir outlet until it is just snug then turn it about one additional half turn NOTE Thread tape should be on the threads of the supplied 3 8 in 9 5 mm fitting If the fitting does not have thread tape installed or you are reusing the fitting apply fresh thread tape to the fittin...

Страница 18: ...ir Connections Fluid Line Connections 1 Insert the 3 8 in 9 5 mm OD tubing through the push through fitting on the top of the tank cover Grab the tubing as it protrudes on the underside of the tank cover and pull the tubing through to form a dip tube The dip tube should be of sufficient length to reach the bottom of the tank when you place the tank cover on the tank Be sure to cut the end of the t...

Страница 19: ...ld down knobs evenly to ensure uniform sealing C Pail Reservoir Systems NOTE Ensure that you plumb the air lines correctly at the inlets and outlets of the dispensing system components The dispensing system will not function properly if the compressed air lines are plumbed incorrectly WARNING Some Dymax fluids can bond skin together in seconds It can also irritate skin eyes and mucous membranes To...

Страница 20: ...upplied 1 4 in 6 3 mm male NPT fitting Inserting the Pail Reservoir in the Tank 1 Remove the cover from the pail reservoir tank by loosening the cover hold down knobs 2 Ensure the metal dip tube is in place and attached to the bottom of the tank cover 3 Open the 5 gal 15 L pail using the pail opener supplied with your pail reservoir system The enclosed technical bulletin describes how to use the t...

Страница 21: ... reservoir Connecting Air to the Ram Pump 1 Verify that all valves are in the Off position before making any connections See Ram Pump Operator s Manual for directions Ensure the pump is mounted and secure per factory use instructions 2 Determine the distance from the factory air supply line to the ram pump location Cut 3 8 in tubing to desired length 3 Locate the push connect air in fitting on the...

Страница 22: ...ressure hose to material outlet side of regulator 6 Connect the free end of the high pressure hose to the material whip supplied with the SG 200 Ensure all connections are tight NOTE Use Teflon sealant tape on all straight connector and fitting threads For best performance keep the hose lengths as short as possible and ensure tight connections between fittings Priming the Ram Pump 1 Connect the ai...

Страница 23: ...cosity cP RAM psi 11 1 ratio Material psi Atomizing psi Tip Nozzle Spray Diameter 8 10 distance 20 000 5 10 10 20 10 20 0 040 8 10 20 000 75 000 20 25 20 25 20 35 0 080 6 8 75 000 100 000 50 75 45 75 50 80 0 120 6 8 11 Continue to run the pump and adjust settings until all air is purged from system 12 Record settings Turn off the pail pump 13 Clean valve nozzle threads and securely replace nozzle ...

Страница 24: ... Good practice is to set up the system so that it operates at a relatively low pressure the ideal reservoir operating pressure as measured and controlled by the precision pressure regulator is 30 to 50 psi 2 1 to 3 5 bar You can use higher pressures if when using the largest needle or tip available you still cannot achieve the desired flow rate 2 Adjust the reservoir pressure to about 15 psi 1 bar...

Страница 25: ...yed is already loaded into the pressure vessel of choice and the air pressure to the material pressure vessel is independently controlled by the material pressure regulator with the air supply off except for bottle drop in tanks which are controlled by an air precision regulator mounted on the lid NOTE The bottle drop in tank s precision air regulator comes with three gauges 0 30 psi 0 2 1 bar 0 6...

Страница 26: ...and forth WARNING Do not look directly into the spray gun Always view needle position from the side Figure 14 Spray Gun Handle 6 Adjust the pressure on the atomizing air regulator 7 Figure 12 between 2 3 psi 0 14 0 21 bar for startup NOTE This pressure setting will only show when the trigger of the handle Figure 14 is pressed 8 To begin the flow of material to the valve take the necessary step s t...

Страница 27: ...e system down place the spray gun into the gun stand and close the compressed air shutoff valve on the system This will stop the flow of air to the system and depressurize the reservoir retainer or tank If the air pressure filter regulator is not being used shut off the shop air from the system 2 Next remove the air pressure from the regulator feeding the valve and trigger handle assembly NOTE The...

Страница 28: ...ing and trigger wiring through handle free and clear 2 Place 345 controller and reservoir in preferred working locations keeping distances between components as short as possible 3 Disconnect 0 25 jack from rear of 345 controller and replace with input from automation PLC controller 4 Route material line to valve inlet 5 Route air actuation lines to valve 6 Mount valve onto arm XYZ head mounting p...

Страница 29: ...quire occasional tightening as wear occurs to prevent leaks through the packing System Cleaning Switching to a Different Fluid To switch your system over from dispensing one fluid to dispensing a new fluid determine if the fluids are compatible with pump and valve components If you are uncertain about material compatibility contact Dymax Application Engineering for assistance If the fluids are com...

Страница 30: ...luid section followed by the 007 Kalrez o ring 19 NOTE An adjustable wrench may be used on the fluid section to separate the parts 11 Clean all the wetted parts thoroughly with an appropriate solvent 12 On the air section use a standard 3 32 Allen key to evenly remove the final two machine screws 20 that thread into the end cap 7 NOTE During removal that the spring 13 will force the air section ap...

Страница 31: ...7 Drop the needle 3 into the piston 9 and assemble with the set screw 14 using an adjustable wrench and 5 64 Allen key to tighten 8 Mount the 014 Buna o ring 16 onto the piston 9 9 Apply a small amount of silicone grease to the inside of the lower air body 9 then drop in the piston and needle assembly 10 Mount the 004 Buna o ring 18 on the end of the needle and slide it down into the groove in the...

Страница 32: ...ll be necessary to re calibrate the micrometer adjust back to the zero position 1 Using the micrometer wrench insert the inside tip of the small end into the orifice of the midsection and rotate it clockwise until the numbered centerline is displayed on a side that can most easily be viewed by an operator Note Valves are supplied from the factory with the center line located 90 left of the fluid i...

Страница 33: ...king nut is loose Tighten packing nut until snug Packing is worn Replace packing Valve does not spray anything Fluid pressure is too low Increase fluid pressure Atomization pressure too high impeding material flow Reduce atomizing pressure increase nozzle size Material cured in fluid section Disassemble valve and clean Spray rate too fast Material PSI too high Reduce material pressure Spray rate t...

Страница 34: ...9 Caps Round Spray Air Cap T15698 Flat Spray Air Cap T15697 Nozzle Round Cap Kit high viscosity 0 045 0 080 0 120 bores T18020 Fittings Material Fitting 1 8 npt x 3 8 OD Tube 90 Elbow T16710 Air Fitting 10 32 x 5 32 OD Tube 90 Elbow T11672 Fluid Line Kits Fluid Line Kit 3 8 OD Black PE 6 ft T16787 Fluid Line Kit 1 4 OD Black PE T16793 Fluid Line Kit 3 8 OD Braided SST Hose with 3 8 Fittings Ram Pu...

Страница 35: ...nded Pressure gauge installed from factory 80 psi 5 5 bar adjust as required if installed Main System Air Regulator Pressure gauge installed from factory 80 psi 5 5 bar Atomized Regulator Pressure gauge installed from factory 2 3 psi higher as required Precision Air Regulator for Material This regulator controls the pressure on the material Set at 15 psi 1 bar for materials under 10 000 cP and 30 ...

Страница 36: ...ment may void your warranty benefits The use of aftermarket replacement parts not supplied or approved by Dymax Corporation will void any effective warranties and may result in damage to the equipment IMPORTANT NOTE DYMAX CORPORATION RESERVES THE RIGHT TO INVALIDATE ANY WARRANTIES EXPRESSED OR IMPLIED DUE TO ANY REPAIRS PERFORMED OR ATTEMPTED ON DYMAX EQUIPMENT WITHOUT WRITTEN AUTHORIZATION FROM D...

Страница 37: ...tenance 29 Material Reservoir 7 Overview of the Spray Gun System 6 Parts 13 Parts Included with System Bottle Reservoir Systems 13 Cartridge Reservoir Systems 13 Pail Reservoir Systems 14 Preparing the System for Use 23 Pressure Regulators 6 Process Flow Diagram 6 Purging Air From the System 23 Reservoir Sizes 4 Retainers Bottle Drop In Reservoirs 10 Cartridge Reservoirs 9 Pail Drop In Reservoirs ...

Страница 38: ...38 Dymax SG 200 High Flow Spray Gun System User Guide ...

Страница 39: ...39 Dymax SG 200 High Flow Spray Gun System User Guide ...

Страница 40: ...g and evaluation by offering equipment trial rental and leasing programs to assist in such testing and evaluations Data sheets are available for valve controllers or pressure pots upon request T18009 MAN068 2 8 2018 Dymax Corporation 1 860 482 1010 info dymax com www dymax com Dymax Oligomers Coatings 1 860 626 7006 info_oc dymax com www dymax oc com Dymax Asia H K Limited 852 2460 7038 dymaxasia ...

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