dymax SG-200 User manual

Dymax SG-200 System User Guide
High-Flow Spray 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

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Dymax SG-200 High-Flow Spray Gun System User Guide
About Dymax®
UV/Visible light-curing adhesives. Systems for light curing, fluid dispensing, and fluid packaging.
Dymax manufactures industrial adhesives including UV light-curable adhesives, epoxy resins, cyanoacrylates, and activator-cured
adhesives. We also manufacture a complete 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 inspection, and increase
throughput. System designs enable stand-alone configuration or integration into your existing assembly line.

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Dymax SG-200 High-Flow Spray Gun System User Guide
Contents
Introduction.................................................................................................................................................... 4
Introduction to the User Guide.................................................................................................................................................. 4
Where to Get Help..................................................................................................................................................................... 4
Safety.............................................................................................................................................................. 4
General Safety Considerations................................................................................................................................................... 4
Specific Safety Considerations ................................................................................................................................................... 5
Overview of the Spray Gun System................................................................................................................. 6
How the Spray Gun System Works ............................................................................................................................................ 6
Description of Main Components .............................................................................................................................................. 6
Types of Reservoir Retainer & Tanks............................................................................................................... 8
Cartridge Reservoir Retainers .................................................................................................................................................... 9
Bottle Reservoir Tank................................................................................................................................................................. 9
Pail Reservoir Tank................................................................................................................................................................... 11
5-Gal Ram Pump System.......................................................................................................................................................... 11
Unpacking & Inspecting Your Shipment ........................................................................................................ 13
Parts Included with the System ............................................................................................................................................... 13
Assembling the System ................................................................................................................................. 14
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
Shutting the System Down....................................................................................................................................................... 27
Restarting the System after Shutdown .................................................................................................................................... 27
Optional Configurations................................................................................................................................ 28
Automated Systems................................................................................................................................................................. 28
Cleaning and Maintenance ........................................................................................................................... 29
System Cleaning........................................................................................................................... Error! Bookmark not defined.
Periodic Maintenance.................................................................................................................. Error! Bookmark not defined.
Troubleshooting............................................................................................................................................ 33
Spare Parts and Accessories.......................................................................................................................... 34
Specifications................................................................................................................................................ 35
System Specifications .............................................................................................................................................................. 35
Warranty ...................................................................................................................................................... 36
Index............................................................................................................................................................. 37

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Dymax SG-200 High-Flow Spray Gun System User Guide
Introduction
Introduction to the User Guide
This guide describes how to use Dymax SG-200 spray gun systems. These systems are comprised of an SG-200
spray gun used in conjunction with any one of the following reservoirs:
■Cartridge reservoir: 12 or 20 oz (300 or 550 mL)
■Bottle reservoir: 0.25 to 1.0 gal (0.5 to 3.78 L)
■Drop-in pail reservoir: 5 gal (15 L)
■Ram pump: 5-gal straight or taper pails
Sections in this guide describe how to assemble, set up and use each type of system.
Intended Audience
Dymax prepared this user guide for experienced process engineers, maintenance technicians, and
manufacturing personnel. If you are new to pneumatically-operated fluid dispensing systems and do not
understand the instructions, contact Dymax Application Engineering to answer your questions before using
the equipment.
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 [email protected].
Please see the back cover for worldwide contact information.
■Dymax adhesive Product Data Sheets (PDS) on our website
■Material Safety Data Sheets (MSDS) provided with shipments of Dymax adhesives
Safety
WARNING! If you use this fluid dispensing system without first reading and understanding
the information in this guide, personal injury can result from the uncontrolled release of high-
pressure gas, injection, or exposure to chemicals. To reduce the risk of injury, read and
understand this guide before assembling and using the Dymax fluid dispensing system.
General Safety Considerations
All users of Dymax spray gun systems should read and understand this user guide before assembling and using
the system.

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Dymax SG-200 High-Flow Spray Gun System User Guide
To learn about the safe handling and use of dispensing fluids, obtain and read the Material Safety Data Sheet
and handling requirements for each fluid before using the fluid. Dymax includes a Material Data Safety Sheet
with each adhesive we sell. You can also request Material Safety Data Sheets for our products on our website.
Specific Safety Considerations
Using Safe Operating Pressures
Pressurizing the components in the dispensing system beyond the maximum recommended pressure can
result in the rupturing of components and serious personal injury. To minimize the risk of rupturing
components and injury, do not exceed the maximum operating pressure of the components in your fluid
dispensing system. (See system specifications on page 35.)
Preventing Injection Injury
Discharging fluids or compressed air from the spray gun against your skin can cause very serious injection
injury. To minimize the risk of injection injury, do not place the spray gun tip in contact with your skin.
Fire and 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 the problem.
Always work in a well-ventilated area designed specifically for spray applications. Some materials
give off flammable fumes. Upon buildup, these fumes can result in a fire or explosion.
Electrically disconnect all the equipment in the spray area and extinguish all open flames or pilot
lights. Do not smoke in the work area.
Do not turn on or off any light switch in the work area while operating or if fumes are present. Do
not operate a gasoline engine in the work area.
Personal Protection for Spraying Applications
WARNINGS! Inhalation and/or constant contact with certain materials can be hazardous to
your health.
To reduce inhalation hazards, ensure adequate ventilation is in place and operational
Protective clothing, organic respirators, face shield, nitrile gloves and hearing protection is
recommended when using spray equipment.

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Dymax SG-200 High-Flow Spray Gun System User Guide
Overview of the Spray Gun System
How the Spray Gun System Works
The Dymax SG-200 spray gun system uses compressed air to pressurize the fluid reservoir. The pressure
pushes fluid from the reservoir through the fluid line to the handheld spray gun. A satellite controller is used
to control valve actuation. When you open the spray gun by squeezing the trigger, fluid flows into the spray
gun where it is atomized and sprays through the spray cap.
Special Features of the Spray Gun System
Features
Benefits
All wetted components on the spray gun are stainless
steel, Teflon®, or Kalrez®
Spray gun is compatible with a greater number of fluids
High-volume flow range of 2.5oz to 20oz per minute
Increased throughput for large part applications
Lightweight spray gun with low trigger resistance
Ergonomic design allows for hours of effortless spraying
Easy adjustment of material flow and spray atomization
Greater dispensing accuracy with less material waste
Pneumatically operated
No electrical power required
Sealed fluid body with no exposure to ambient conditions
Easy shutdown, material protection
Safety relief valves on bottle and pail reservoir tanks
Provides a safer system for users
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 of reservoir pressure
When replacing system parts, ensure the quality of replacement parts matches the quality of the original
equipment parts to maintain the safety and operational performance of the system.
Description of Main Components
Air Filter/Regulator—The air filter/regulator enables you to reduce the pressure of the plant incoming air to a
pressure useable by the dispensing system. The air filter/regulator includes:
a. Filter bowl with coalescing filter to remove solid and fluid contaminants from the compressed air.
b. Pressure gauge that displays the pressure of air after it is regulated.
c. Pressure control knob that enables you to adjust the pressure of the air.
d. Shutoff valve that enables you to start and stop the flow of air into the system. In the Closed position,
the shutoff valve also depressurizes the system by exhausting air through its exhaust port.
Air Precision Regulator—The air precision regulator enables you to precisely control the air pressure in the
fluid reservoir. The air precision regulator includes:

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Dymax SG-200 High-Flow Spray Gun System User Guide
a. Pressure gauge that displays the pressure in the fluid reservoir. A 0- to 60-psi (0- to 4.1-bar) pressure
gauge is installed on the air regulator. Two alternative-scale pressure gauges (0-to-30 psi and 0-to-
100psi) are supplied and you can substitute these gauges for the installed gauge to match your
operating pressure requirements.
b. Pressure control knob that enables you to adjust the pressure of the air entering the reservoir.
Compressed Air Line—The air line consists of transparent blue polyurethane tubing designed for compressed
air use.
Reservoir Retainer or Reservoir Tank—The SG-200 spray system is available in the following configurations:
a. Cartridge Reservoir Retainer—A cartridge reservoir retainer is a plastic housing with a cover that holds
a cartridge reservoir. The top of the retainer seals the top of the cartridge reservoir. The bottom of the
retainer includes a hole from which the outlet port of the cartridge reservoir protrudes. Pressurizing the
top of the retainer pushes the cartridge reservoir piston down which pushes the fluid from the outlet
port.
b. Bottle Reservoir Tank and Pail Reservoir Tank—Bottle and pail reservoir tanks are similar in
operational design. For example, you place an opened reservoir bottle (plastic polypropylene container
with a screw-on cap for bottle reservoir tanks or 5-gal (15-L) plastic polyethylene pails with a pry-off
cover for pail reservoir tanks) in the reservoir tank and seal the tank. A flexible or rigid dip tube with an
outlet on the tank cover is submerged in the fluid. When you pressurize the bottle reservoir tank, fluid
is driven up the dip tube 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-dispensing line consists of black light-blocking polyethylene tubing compatible with the
chemistries of Dymax fluids and many types of commercial adhesives and fluids.
Handheld Spray Gun & Regulator Assembly—The handheld spray gun enables you to easily spray fluids and
provides trigger control with optional foot pedal override control. Spraying begins when the operator
squeezes the trigger and stops when the trigger is released. The atomizing function on the SG-200 is an
“always on” mode, ensuring the heaviest materials atomize upon dispense. The spray gun includes a kit of
caps and nozzles of different diameters, allowing users to adjust per flow rates and materials being sprayed.
The spray gun assembly also includes two regulators. One for controlling the operating air for the gun and the
other for controlling the atomizing air used to create the spray.
DVC-345 Digital Valve Controller—The DVC-345 digital valve controller’s internal 4-way solenoid valve
operates Dymax or other pneumatic dispense valves. This controller may be operated via footswitch, manual
front panel switch, or remote PLC. Cycle time may be set in a range from .001 to 9.999 seconds in .001-second
increments. Front panel mounted controls provide a valve prime function, cycle adjustment, manual or timed
dispense, and a multi-color LCD timer display.
Spray Gun Stand—The spray gun stand provides a convenient way to hold the handheld spray gun in the
recommended position when it is not in use.

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Dymax SG-200 High-Flow Spray Gun System User Guide
Figure 1. Typical Setup of the Spray Gun System (Shown with 20-oz Fluid Reservoir)
Material Reservoir
(Cartridge Reservoir Retainer
Shown - Holds Cartridge
Reservoir Inside)
Air Filter/Regulator
Fluid Line
Plant Compressed Air In, ¼" nptf
DVC-345 Controller
Handheld Spray Gun
Atomizing Air Regulator
Spray Gun Stand
Compressed Air Line
Material Pressure Regulator
Regulator Stand

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Dymax SG-200 High-Flow Spray Gun System User Guide
Types of Reservoir Retainer & Tanks
Depending on the dispensing system you ordered, your system includes:
■Cartridge reservoir retainer - for high-flow delivery to small or hard-to-access applications
■Bottle/pail reservoir tank - for applications requiring volume delivery of low/medium-viscosity
materials over large areas
■Ram pump system - for applications requiring volume delivery of high-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 with
material for dispensing.
Figure 2. Cartridge Reservoir Retainer
Cartridge Reservoir Retainer
Retainer Cover
Compressed Air Inlet
Regulated Compressed Air In
Fluid Out
*Note
Repackaging Dymax material voids
warranty and is not recommended

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Dymax SG-200 High-Flow Spray Gun System User Guide
Bottle Reservoir Tank
The bottle reservoir tank includes a push-through fitting on the tank cover. You push the fluid dispensing line
through the fitting and into the tank to form a dip tube. When the tank 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
Pressure Adjustment Knob
Pressure Relief Valve
Pressure Gauge

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Dymax SG-200 High-Flow Spray Gun System User Guide
Pail Reservoir Tank
The pail reservoir tank includes a metal dip tube with an outlet fitting on the tank cover. If desired, you can
configure the dip tube as a flexible tube using the supplied dispensing line by pushing the line through the
supplied push-through fitting.
The fluid dispensing line is connected to the dip tube fitting. The pressure in the tank pushes the fluid up the
dip 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 are available
from Dymax.
Air Precision Regulator
Adhesive Outlet Port
Compressed Air Shutoff Valve
Filler Cap
Compressed Air Filter
Pail Reservoir Tank
Tank Cover
Cover Hold-Down Knob
Regulated Plant Compressed Air In
Fluid Out
Pressure Gauge

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Dymax SG-200 High-Flow Spray Gun System User Guide
5-Gal Ram Pump System
The 5-gallon ram pump system includes a positive displacement, vertical ram head with interchangeable
collars for straight or tapered pails. The ram pump operates at 80-100 psi and offers an 11:1 pump ratio. A
downstream regulator (1,200 psi input max) is included, and maintains consistent output flow across 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 System Components
Material Out
Ram Head- 5-Gallon Pails
> Tapered pail configuration
> Straight pail configuration
Compressed Air In
Material Pressure
Regulator
Manifold
Bleeder Port

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Dymax SG-200 High-Flow Spray Gun System User Guide
Unpacking & Inspecting Your Shipment
Your system arrives in one or more boxes depending upon which system you ordered. Inspect the boxes for
damage and notify the shipper of box damage immediately.
Open each box and check for equipment damage. If parts are damaged, notify the shipper and submit a claim
for the damaged parts. Contact Dymax so that we can ship new parts to you immediately.
Check that the parts included in your order match those listed. If parts are missing, contact your local Dymax
representative or our Customer Support team to resolve the problem.
Parts Included with the System
Your Dymax SG-200 spray gun system can be one of four types: cartridge reservoir system, bottle reservoir
system, pail reservoir system, or a system with high pressure, positive displacement ram pump. Each type of
system includes different parts as described below.
Parts Included in Cartridge Reservoir Systems
■SG-200 spray 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 (550-mL) cartridge reservoir
■One empty, reusable cartridge reservoir (shipped inside retainer)
Parts Included in Bottle Drop-In Reservoir Systems
■SG-200 spray gun with controlling air regulators
■DVC-345 timed shot controller
■Spray gun stand
■Air filter/regulator
■Air precision regulator (mounted on bottle reservoir tank) 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
■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” MNPT comp
■One bottle reservoir tank fits 0.26-gal (1-L), 0.5-gal (2-L) and 1.0-gal (3.78-L) bottle reservoirs

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Dymax SG-200 High-Flow Spray Gun System User Guide
Parts Included in Pail Reservoir Systems
■SG-200 spray gun with controlling air regulators
■DVC-345 timed shot controller
■Spray gun stand
■Air precision regulator (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
■A drop-in reservoir tank for up to 5-gal (15-L) pails
■Incoming air filter with dump
■Incoming shutoff valve
■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
Parts Included in 5-Gallon Ram Pump Systems
■SG-200 spray gun with controlling air regulators
■DVC-345 timed shot controller
■Spray gun stand
■Air precision regulator (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—high-pressure, 3/8-in braided hose x 6 ft
■Fluid line kit—fittings, swivels kit: 3/8-in MNPT x 3/8-in MNPT comp
Assembling the System
Utilities Required
The spray gun system requires 80 to 100 psi (4.1 to 6.9 bar) of clean, dry, compressed air, nitrogen, or other
inert gas. A compressed air-flow rate of 12-15 cfm provides sufficient flow for all systems.
Choosing and Installing an Alternative Pressure Gauge
Systems using a bottle or pail reservoir tank include a 0- to 60-psi (0- to 4.1-bar) pressure gauge installed on
the air precision regulator. The system also includes two alternative pressure gauges—0 to 30 psi or 0 to 100

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Dymax SG-200 High-Flow Spray Gun System User Guide
psi (0 to 2 bar or 0 to 6.9 bar)—which can be installed if needed. If you are not sure of the
material/atomization pressure range at which you will run the system, start with the installed pressure gauge
and change to one of the alternative pressure gauges if needed.
Initial Setup of the Spray Gun
The SG-200 spray gun is designed for ease of setup. All air connections come pre-installed except for the
connection between the shop air and the air filter/regulator and the fluid line must be connected between the
materials reservoir and the spray gun. Before operation, check that the material lines and air lines and fitting
connections are secure and 100% inserted.
Connecting the Air 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 accordance
with the OEM instructions supplied with the air filter/regulator. Failing to securely mount the inlet
pressure regulator in the upright position will prevent the regulator from removing moisture and
particulates from the incoming compressed air.
3. Connect factory air to the air filter/regulator. Be sure the regulator outlet knob is in the off position.
Figure 6. Supply & Atomizing Control Valve Stand
Air Out to Reservoir
Dual Port
Atomizing Regulator
Material Pressure Regulator
Air Out to DVC-345
Connect to Air Filter/
Regulator

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Dymax SG-200 High-Flow Spray Gun System User Guide
Connecting the DVC-345 Controller
1. Locate a convenient, clean position to place the controller.
NOTE: If using a spray booth or environment where electrical devices are forbidden, position the controller
outside of the immediate environment.
2. Connect the power supply to 345 Controller.
3. Connect the tubing from the Spray Gun to the “A” and “B” Outlets located on the back of the Controller.
The red tubing connects to Port A. The blue tubing connects to Port B. (Figure 7)
4. Connect the ¼" 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 –DVC-345 Valve Controller User Guide.
7. Test the valve actuation by depressing the trigger on the spray gun. If the gun is not working properly,
check the air line connections and controller settings.
WARNING! Always aim the spray nozzle away from yourself and others to reduce risk of accident or
injury.

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Dymax SG-200 High-Flow Spray Gun System User Guide
Connecting the Material Reservoir
A—Cartridge Reservoir Systems
Prepare the Cartridge Reservoir
WARNING! Some Dymax fluids can bond skin together in seconds. It can also irritate skin,
eyes, and mucous membranes. To minimize the risk of bonded skin or irritation, wear protective
gloves and eyewear when working with Dymax fluids and the hand-held spray gun system.
1. Unscrew the cover from the cartridge reservoir retainer. Remove the empty cartridge reservoir if present.
2. Remove the plastic cover from the top of a Dymax or other cartridge reservoir.
3. Place the cartridge reservoir in the retainer so that the fluid outlet at the bottom of the cartridge extends
through the hole in the bottom of the retainer.
4. Screw the cover back onto the retainer.
5. To prevent low-viscosity fluids from flowing from the cartridge reservoir when you remove the outlet
plug, hold the retainer upside down.
6. 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 fitting threads to
prevent fluid leaks.
Fluid Line Connections
1. Connect one end of the fluid line to the
reservoir outlet fitting by pushing the line
into the fitting. Attach the other end of
the fluid line to the fluid inlet fitting on
the spray gun.
2. Allow the cartridge retainer to hang
freely below the handle. Use securing
clips to harness the pneumatic tubing to
the cartridge. This prevents the cartridge
from swinging freely while spraying, and
keeps lines neat and orderly during use.
Connect Air Line to Cartridge
Reservoir
Connect the material pressure regulator
(air out) to air inlet fitting on the cartridge
reservoir.
Figure 8. Cartridge Reservoir Connections
fluid line
Air line –Connects from Material Pressure
Gauge to Cartridge Retainer

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Dymax SG-200 High-Flow Spray Gun System User Guide
B—Bottle Drop-In 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 you plumb the compressed air lines incorrectly.
WARNING! Some Dymax fluids can bond skin together in seconds. It can also irritate skin,
eyes, and mucous membranes. To minimize the risk of bonded skin or irritation, wear protective
gloves and eyewear when working with Dymax fluids and the hand-held spray gun system.
Exposing Dymax adhesives to light causes most Dymax adhesives and fluids to begin curing.
Hence, to prevent unintentional curing during the loading of bottle reservoirs, have the reservoir
tank ready to accept the bottle reservoir and complete the loading process quickly after opening
the bottle reservoir.
Figure 9. Bottle Drop-In Reservoir 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 tube at a 45° angle to ensure free flow of material at
bottom of tank.
2. Cut the other end of the dispensing line to a working length (6 ft or less recommended). The dispensing
line should be cut as short as possible to reduce pressure losses in the line, but long enough to enable you
to reach and work comfortably with the spray gun in the work area.
3. Attach the fluid dispensing line to the fitting on the spray gun.
NOTE: For optimal dispensing performance, the length of all fluid lines should be as short as possible to
reduce fluid pressure drop and other variations that may affect precision dispensing
Air line –Connects from
Material Pressure Regulator to
Precision Air Regulator’s Air
Inlet
Fluid Line

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Dymax SG-200 High-Flow Spray Gun System User Guide
Connect Air Line to Reservoir
Connect the air line from the material pressure regulator (air out) to the air inlet fitting on the precision
regulator on the tank cover (Figure 9).
Inserting the Bottle Reservoir in the Tank
1. Remove the cover from the bottle reservoir tank by loosening the cover hold-down knobs.
2. Unscrew the cover from a 0.26-gal (1-L) or 0.5-gal (2-L) bottle reservoir and place the reservoir into the
tank. Complete this step quickly to prevent initiation and curing of light-sensitive fluids.
3. Install the tank cover on the tank, ensuring the dip tube is inserted to the bottom of the bottle reservoir.
Complete this step quickly to prevent curing of light-sensitive fluids.
4. Tighten the cover hold-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 minimize the risk of bonded skin or irritation, wear protective
gloves and eyewear when working with Dymax fluids and the hand-held spray gun system.
Exposing Dymax adhesives to light causes most Dymax adhesives and fluids to begin curing.
Hence, to prevent unintentional curing during the loading of pail reservoirs, have the reservoir
tank ready to accept the pail reservoir and complete the loading process quickly after opening the
pail reservoir.
Figure 10. Pail Reservoir Connections
Air line –Connects from Material Pressure
Regulator to Tank Filter.
Fluid Line

20
Dymax SG-200 High-Flow Spray Gun System User Guide
Fluid Line Connections
1. Determine the working length of the dispensing line from pail tank to the spray gun and cut the line to
length. The fluid line should be cut as short as possible to reduce pressure losses in the line, but long
enough to enable you to reach and work comfortably with the spray gun in the work area.
NOTE: If you are reducing the dispensing line from 3/8- to 1/4-in. (9.5- to 6.3-mm), cut the 3/8-in.
(9.5-mm) line about 12 in. (30.5 cm) shorter than needed. Cut a 12-in. (30.5 cm) length of 1/4-in.
(6.3-mm) OD tubing. Use the 3/8- to 1/4-in. (9.5- to 6.3-mm) OD tubing reducer to connect the two lines
together (Figure 7).
2. Connect one end of the dispensing line to the outlet fitting on the tank cover by pushing the line into the
fitting.
3. Connect the other end of the line to the fluid inlet fitting on the spray gun.
Connect Air Line to Reservoir
1. Ensure your plant air supply is regulated to 80 to 100 psi (5.5 to 6.9 bar).
2. Ensure the compressed air shutoff valve on the tank cover is in the Closed position.
3. Connect the air line from the material pressure regulator (air out) to the inlet of the filter on the tank
cover using a customer-supplied 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 tool.
4. Quickly lift the pail reservoir and place it in the tank.
5. Quickly install the tank cover on the tank, ensuring the dip tube is inserted in the pail reservoir.
6. Tighten the cover hold-down knobs evenly to ensure uniform sealing of the tank.
D—Ram “Pail” Pump 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! Pressurizing the components in the dispensing system beyond the maximum
recommended pressure can result in the rupturing of components and serious personal injury. To
minimize the risk of rupturing components and injury, do not exceed the maximum operating
pressure of the components in your fluid dispensing system.
Discharging fluids or compressed air against your skin can cause very serious injection injury. To
minimize the risk of injection injury, do not place the spray cap in contact with your skin.