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