Nordson Rhino AB Reference guide

RhinoAB and AC Unloaders
Customer Product Manual
Part 1609834−02
Issued 8/18
NORDSON CORPORATION AMHERST, OHIO USA
For parts and technical support, call the Industrial Coating
Systems Customer Support Center at [phone] or
contact your local Nordson representative.
This document is subject to change without notice.
Check http://emanuals.nordson.com for the latest version.

Part 1609834−02 E2018 Nordson Corporation
Contact Us
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
555 Jackson Street
Amherst, OH 44001
Notice
This is a Nordson Corporation publication which is protected by copyright.
Original copyright date 2018. 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
Rhino, Nordson, and the Nordson logo are registered trademarks of
Nordson Corporation.
All other trademarks are the property of their respective owners.

Table of Contents i
Part 1609834−02
E2018 Nordson Corporation
Table of Contents
Safety 1-1..................................................
Introduction 1-1.............................................
Qualified Personnel 1-1......................................
Intended Use 1-1...........................................
Regulations and Approvals 1-1...............................
Personal Safety 1-2.........................................
High-Pressure Fluids 1-2..................................
Fire Safety 1-3.............................................
Halogenated Hydrocarbon Solvent Hazards 1-4..............
Action in the Event of a Malfunction 1-4........................
Disposal 1-4...............................................
Safety Labels 1-5...........................................
Overview 2-1...............................................
Unloader Components 2-1....................................
AB Unloader 2-2..........................................
AC Unloader 2-3..........................................
Pneumatic Control Module 2-4................................
Control Module Symbols and Icons 2-6......................
AB Pump 2-7...............................................
Theory of Operation 2-8...................................
Air Motor 2-8...........................................
Hydraulic Section −Suction Stroke 2-9....................
Hydraulic Section −Pressure Stroke 2-9...................
Plunger Lubrication 2-9..................................
AC Pump 2-11...............................................
Theory of Operation 2-12...................................
Air Motor 2-12...........................................
Hydraulic Section 2-13...................................
Bleed Valve 2-15.............................................
Follower Modules 2-16........................................
Accessories 2-18.............................................
Container Level Light Tower 2-18.............................
Container Hold-Down 2-19..................................
Material Output Gauge 2-20.................................
Specifications 2-21...........................................
Dimensions and Weight 2-21................................
Connections 2-21..........................................
Consumable Items 2-21.......................................
Adhesives, Sealants, and Lubricants 2-21.....................
Solvent Chamber Fluid 2-21.................................
Installation 3-1.............................................
Installation Procedure 3-1....................................
Unpack the Unloader 3-2...................................
Install the Unloader 3-2....................................

Table of Contents
ii
Part 1609834−02 E2018 Nordson Corporation
Operation 4-1..............................................
First-Time Startup 4-1........................................
Control Module Components 4-4............................
Container Change Procedure 4-6..............................
Pump Operation 4-8.........................................
Basic Operation 4-8.......................................
Pneumatic Controls 4-8....................................
Air Motor Supply 4-8......................................
AC Unloader 4-8.......................................
Elevator and Blow-Off Air Supply 4-9........................
Maintenance 4-10............................................
Troubleshooting 5-1........................................
Repair 6-1.................................................
Reference Documentation 6-1................................
Parts 7-1...................................................
Introduction 7-1.............................................
Reference Documentation 7-1................................

Safety 1-1
Part 1609834−02
E2018 Nordson Corporation
Section 1
Safety
Introduction
Read and follow these safety instructions. Task- and equipment-specific
warnings, cautions, and instructions are included in equipment
documentation where appropriate.
Make sure all equipment documentation, including these instructions, is
accessible to persons operating or servicing equipment.
Qualified Personnel
Equipment owners are responsible for making sure that Nordson equipment
is installed, operated, and serviced by qualified personnel. Qualified
personnel are those employees or contractors who are trained to safely
perform their assigned tasks. They are familiar with all relevant safety rules
and regulations and are physically capable of performing their assigned
tasks.
Intended Use
Use of Nordson equipment in ways other than those described in the
documentation supplied with the equipment may result in injury to persons
or damage to property.
Some examples of unintended use of equipment include
Susing incompatible materials
Smaking unauthorized modifications
Sremoving or bypassing safety guards or interlocks
Susing incompatible or damaged parts
Susing unapproved auxiliary equipment
Soperating equipment in excess of maximum ratings
Regulations and Approvals
Make sure all equipment is rated and approved for the environment in which
it is used. Any approvals obtained for Nordson equipment will be voided if
instructions for installation, operation, and service are not followed.

Safety
1-2
Part 1609834−02 E2018 Nordson Corporation
Personal Safety
To prevent injury, follow these instructions.
SDo not operate or service equipment unless you are qualified.
SDo not operate equipment unless safety guards, doors, or covers are
intact and automatic interlocks are operating properly. Do not bypass or
disarm any safety devices.
SKeep clear of moving equipment. Before adjusting or servicing moving
equipment, shut off the power supply and wait until the equipment
comes to a complete stop. Lock out power and secure the equipment to
prevent unexpected movement.
SRelieve (bleed off) hydraulic and pneumatic pressure before adjusting or
servicing pressurized systems or components. Disconnect, lock out,
and tag switches before servicing electrical equipment.
SWhile operating manual spray guns, make sure you are grounded.
Wear electrically conductive gloves or a grounding strap connected to
the gun handle or other true earth ground. Do not wear or carry metallic
objects such as jewelry or tools.
SIf you receive even a slight electrical shock, shut down all electrical or
electrostatic equipment immediately. Do not restart the equipment until
the problem has been identified and corrected.
SObtain and read Safety Data Sheets (SDS) for all materials used.
Follow the manufacturer’s instructions for safe handling and use of
materials, and use recommended personal protection devices.
SMake sure the spray area is adequately ventilated.
STo prevent injury, be aware of less-obvious dangers in the workplace
that often cannot be completely eliminated, such as hot surfaces, sharp
edges, energized electrical circuits, and moving parts that cannot be
enclosed or otherwise guarded for practical reasons.
High-Pressure Fluids
High-pressure fluids, unless they are safely contained, are extremely
hazardous. Always relieve fluid pressure before adjusting or servicing high
pressure equipment. A jet of high-pressure fluid can cut like a knife and
cause serious bodily injury, amputation, or death. Fluids penetrating the
skin can also cause toxic poisoning.
If you suffer a fluid injection injury, seek medical care immediately. If
possible, provide a copy of the SDS for the injected fluid to the health care
provider.

Safety 1-3
Part 1609834−02
E2018 Nordson Corporation
The National Spray Equipment Manufacturers Association has created a
wallet card that you should carry when you are operating high-pressure
spray equipment. These cards are supplied with your equipment. The
following is the text of this card:
WARNING: Any injury caused by high pressure liquid can be serious. If
you are injured or even suspect an injury:
SGo to an emergency room immediately.
STell the doctor that you suspect an injection injury.
SShow him this card
STell him what kind of material you were spraying
MEDICAL ALERT—AIRLESS SPRAY WOUNDS: NOTE TO PHYSICIAN
Injection in the skin is a serious traumatic injury. It is important to treat the
injury surgically as soon as possible. Do not delay treatment to research
toxicity. Toxicity is a concern with some exotic coatings injected directly into
the bloodstream.
Consultation with a plastic surgeon or a reconstructive hand surgeon may
be advisable.
The seriousness of the wound depends on where the injury is on the body,
whether the substance hit something on its way in and deflected causing
more damage, and many other variables including skin microflora residing
in the paint or gun which are blasted into the wound. If the injected paint
contains acrylic latex and titanium dioxide that damage the tissue’s
resistance to infection, bacterial growth will flourish. The treatment that
doctors recommend for an injection injury to the hand includes immediate
decompression of the closed vascular compartments of the hand to release
the underlying tissue distended by the injected paint, judicious wound
debridement, and immediate antibiotic treatment.
Fire Safety
To avoid a fire or explosion, follow these instructions.
SGround all conductive equipment. Use only grounded air and fluid
hoses. Check equipment and workpiece grounding devices regularly.
Resistance to ground must not exceed one megohm.
SShut down all equipment immediately if you notice static sparking or
arcing. Do not restart the equipment until the cause has been identified
and corrected.
SDo not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
SDo not heat materials to temperatures above those recommended by
the manufacturer. Make sure heat monitoring and limiting devices are
working properly.

Safety
1-4
Part 1609834−02 E2018 Nordson Corporation
Fire Safety (contd)
SProvide adequate ventilation to prevent dangerous concentrations of
volatile particles or vapors. Refer to local codes or your material SDS
for guidance.
SDo not disconnect live electrical circuits when working with flammable
materials. Shut off power at a disconnect switch first to prevent
sparking.
SKnow where emergency stop buttons, shutoff valves, and fire
extinguishers are located. If a fire starts in a spray booth, immediately
shut off the spray system and exhaust fans.
SShut off electrostatic power and ground the charging system before
adjusting, cleaning, or repairing electrostatic equipment.
SClean, maintain, test, and repair equipment according to the instructions
in your equipment documentation.
SUse only replacement parts that are designed for use with original
equipment. Contact your Nordson representative for parts information
and advice.
Halogenated Hydrocarbon Solvent Hazards
Do not use halogenated hydrocarbon solvents in a pressurized system that
contains aluminum components. Under pressure, these solvents can react
with aluminum and explode, causing injury, death, or property damage.
Halogenated hydrocarbon solvents contain one or more of the following
elements:
Element Symbol Prefix
Fluorine F “Fluoro-”
Chlorine Cl “Chloro-”
Bromine Br “Bromo-”
Iodine I “Iodo-”
Check your material SDS or contact your material supplier for more
information. If you must use halogenated hydrocarbon solvents, contact
your Nordson representative for information about compatible Nordson
components.
Action in the Event of a Malfunction
If a system or any equipment in a system malfunctions, shut off the system
immediately and perform the following steps:
SDisconnect and lock out system electrical power. Close hydraulic and
pneumatic shutoff valves and relieve pressures.
SIdentify the reason for the malfunction and correct it before restarting the
system.
Disposal
Dispose of equipment and materials used in operation and servicing
according to local codes.

Safety 1-5
Part 1609834−02
E2018 Nordson Corporation
Safety Labels
Refer to Table 1-1 for the text of the safety labels and see Figure 1-1 for the
location of the safety labels.
The safety label is provided to help operate and maintain equipment safely.
Table 1-1 Safety Labels
Item Description
1.
WARNING: The following information is important to the health and safety of employees.
Failure to follow the messages in this safety notice can result in personal injury, including
death, or damage to the equipment or property.
SAllow only personnel with appropriate training and experience to operate or service
the equipment. The use of untrained or inexperienced personnel to operate or service
the equipment can result in injury, including death, to themselves or others, and
damage to the equipment.
SDO NOT place any body part or portion of the body between the drum and the air
manifold, or between the crossbar and the platen/follower plate.
STo safely operate and maintain this equipment, refer to the Safety, Operation, and
Maintenance sections in the applicable product manual. Manuals are available at
www.emanuals.nordson.com.
SIt is very important to remember that when the ram is in the Neutral position, it is not
mechanically locked. Air pressure remains in the ram cylinders. Small air leaks in the
circuit could cause the ram to move. Use support blocks to prevent the ram from
moving when necessary.
SAvoid servicing this equipment from the rear. If service from the rear is unavoidable,
lock out all electric and pneumatic power sources.
2. WARNING: Lock out all electrical and pneumatic power sources. DO NOT place hands or
body between the platen/drum and crossbar.

Safety
1-6
Part 1609834−02 E2018 Nordson Corporation
AB UNLOADER AC UNLOADER
2
2
1
1
1609049
10016369
Figure 1-1 Safety Label Location

Overview 2-1
Part 1609834−02
E2018 Nordson Corporation
Section 2
Overview
Unloader Components
Refer to Table 2-1 and see Figures 2-1 and 2-2.
Table 2-1 Unloader Components
Item Description
1Container Level Light Tower: Indicates when the container is low or empty. The low
indicator is customer adjustable.
2
Pneumatic Control Module: Contains the air pressure regulators and gauges for the
pump air motor and the elevator control valve for the operation of the unloader. The
module also contains all of the pneumatic valves for the operation of the unloader and the
5-micron filter for the control signal air supply.
3
Solvent Chamber: Surrounds the pump plunger and contains fluid that lubricates the
plunger and packing gland seals. The fluid keeps the material from hardening on the
plunger and minimizes wear on the packing gland seals.
4Solvent Chamber Drain Port: Drains the solvent.
5
Bleed Port: Relieves the air pressure between the follower plate and the material
container during container changes. When the bleeder stem is removed, air and material
exits through the bleed port on the follower plate.
6Base Plate: The base of the unloader; must be secured to the floor.
7Material Outlet Port: The material outlet port of the pump. See the Specifications section
for port connection size.
8
Bleed Valve: Designed for use as a bleed port at the highest point of the pump hydraulic
section. The port is used to bleed air from the pump section during initial startup and
container changes.
9Drum-Centering Shoes (AC unloader)/Pail Locators (AB unloader): Designed for
positioning the material container below the follower plate.
10
Blow-Off Check Valve: Opened with line pressure air to remove the follower from the
material container during material changes. Air is supplied to the check valve from the
control module when the blow-off valve is actuated, and only when the elevator control is
in the Ram Up position.
11
Follower Plate Module: Contains an elastomer seal(s) that creates a sealed
compartment when lowered into a material container. The downward movement of the
follower plate forces material into the hydraulic section of the pump.
12 Pump: Air-powered, dual-acting, positive-displacement pump consisting of an air motor
and a hydraulic section.
13
Pressure Relief Valve Assembly (AC unloader only): Used in the air supply circuit to
limit the maximum pressure to the pump air motor, thus limiting the maximum pump output
pressure.

Overview
2-2
Part 1609834−02 E2018 Nordson Corporation
AB Unloader
Refer to Table 2-1 and see Figure 2-1.
10014972
12
1
2
3
5
7
6
8
9
10
11
4
Figure 2-1 AB Unloader
1. Light tower
2. Pneumatic control module
3. Solvent chamber
4. Solvent chamber drain port
5. Bleed port
6. Base plate
7. Material outlet port
8. Bleed valve
9. Pail hold-down
10. Blow-off check valve
11. Follower plate module
12. Pump

Overview 2-3
Part 1609834−02
E2018 Nordson Corporation
AC Unloader
Refer to Table 2-1 and see Figure 2-2.
1001508
6
12
1
13
2
7
9
6
3
8
5
11
10
Figure 2-2 AC Unloader
1. Light tower
2. Pneumatic control module
3. Solvent chamber
5. Bleed port
6. Base plate
7. Material outlet port
8. Bleed valve
9. Drum-centering shoes
10. Blow-off check valve
11. Follower plate module
12. Pump
13. Pressure relief valve

Overview
2-4
Part 1609834−02 E2018 Nordson Corporation
Pneumatic Control Module
Refer to Table 2-2 and see Figure 2-3. The controls are the same for both
the AC and AB unloaders.
Table 2-2 Control Module Components
Item Description
1Air Motor Regulator: Controls the air to the pump.
2Control Module Lockout Valve: Allows the control module to be locked out of receiving
input air pressure for service of the unloader.
3Elevator Air Regulator: Controls the air to the elevator cylinder.
4
Material Container Blow-Off Valve: Activates the flow of the air to the blow-off check
valve located on the follower plate, forcing air beneath the bottom of the follower plate and
into the container. This pressure keeps the container on the base plate as the ram
cylinders move the pump and follower upward.
5Air Motor Lockout Valve: Allows the air motor to be locked out of receiving air pressure
from the control module for service.
6Air Motor Pressure Gauge: Displays the pressure to the air motor.
7Pneumatic Reset Valve: Resets the control module’s signal valves when pressed.
8Elevator Air Pressure Gauge: Displays the pressure to the elevator cylinder.
9
Elevator Control Valve: Initiates ram movement.
 Ram Up position raises the elevator and the follower plate assembly.
 Ram Down position lowers the elevator and follower plate assembly into the material
container.
 Neutral position stops elevator movement. Neutral is not a locked and secured
position. The follower plate may drift downward over time.

Overview 2-5
Part 1609834−02
E2018 Nordson Corporation
9
7
8
1
2
3
4
6
5
10015696
Figure 2-3 Control Module
1. Air motor regulator
2. Control module lockout valve
3. Elevator air regulator
4. Material container blow-off valve
5. Air motor lockout valve
6. Air motor pressure gauge
7. Pneumatic reset valve
8. Elevator air pressure gauge
9. Elevator control valve

Overview
2-6
Part 1609834−02 E2018 Nordson Corporation
Control Module Symbols and Icons
See Figure 2-4.
Elevator Icon
Pressure Measurement
Symbol
Pneumatic
Reset Symbol
Material Container
Blow−Off Icon
Air Motor Icon
Pressure Control
Symbol
Up Icon Down Icon
Push Button
Off Icon
Push Button
On Icon
Figure 2-4 Control Module Symbols and Icons

Overview 2-7
Part 1609834−02
E2018 Nordson Corporation
AB Pump
See Figure 2-5 and refer to Table 2-3 for a description of the AB pump
components.
10014972
1
2
3
5
4
6
Figure 2-5 Rhino AB Pump
1. Air motor valves
2. Split coupling
3. Solvent chamber drain port
4. Hydraulic section
5. Air motor
6. Solvent chamber
Table 2-3 Rhino AB Pump Components
Item Description
1Air Motor Valves: Control the direction of the pump drive train.
2Split Coupling: Connects the air motor coupling shaft to the hydraulic section plunger rod.
3Solvent Chamber Drain Port: Drains the solvent.
4Hydraulic Section: Pressurizes the material and forces it out of the pump.
5Air Motor: Drives the hydraulic section.
6
Solvent Chamber: Surrounds the pump plunger and contains fluid that lubricates the plunger
and packing gland seals. The fluid keeps the material from hardening on the plunger and
minimizes wear on the packing gland seals.

Overview
2-8
Part 1609834−02 E2018 Nordson Corporation
Theory of Operation
The following paragraphs provide theory of operation for a typical pump air
motor and hydraulic section.
Air Motor
See Figure 2-6.
The air motor drives the hydraulic section. A five-port, three-position (5/3)
main air control valve controls the direction of the air motor shaft movement.
When the air motor piston moves up and down, the proximity sensor detects
a magnet on the piston. The proximity sensor sends momentary signals to
a pilot valve. The pilot valve sends a positive continuous signal to the main
air motor control valve for each direction of travel.
10016282_125
Pilot Valve
Main Air
Control Valve
Figure 2-6 Rhino 125-mm Air Motor

Overview 2-9
Part 1609834−02
E2018 Nordson Corporation
Hydraulic Section −Suction Stroke
See Figure 2-7.
Air below the air motor piston pulls the plunger (6) upward. The pressure
ball check (7) closes and the siphon ball check (8) opens. The material
above the pressure ball check is forced out the outlet port (3) while new
material is pulled in through the inlet port (9). The packing glands prevent
pressurized coating material from leaking past the plunger (6).
As the piston reaches the top of its stroke, the air motor proximity sensor
output shifts the air valve spool, directing supply air to the top of the piston
and exhausting the air below the piston.
Hydraulic Section −Pressure Stroke
See Figure 2-7.
Air above the piston pushes the piston and plunger (6) down. The siphon
ball check (8) closes and the pressure ball check (7) opens. Material below
the pressure ball check is forced up through the plunger (6) and out the
outlet port (3). When the piston reaches the bottom of its stroke, the air
motor proximity sensor output shifts the air valve spool and the suction
stroke begins again.
Plunger Lubrication
See Figure 2-7.
The solvent chamber (4) contains solvent chamber fluid that lubricates the
upper part of the plunger (6) and prevents the upper packings from wearing
excessively. The coating material being pumped lubricates the lower
packings.
NOTE: Dispense material leaking past the upper packing gland (2) will
discolor the solvent chamber fluid and cause its level to rise. A small
amount of leakage is normal. If the solvent chamber (4) fills quickly and
overflows the packings need to be replaced. Both upper and lower
packings should be replaced at the same time.

Overview
2-10
Part 1609834−02 E2018 Nordson Corporation
1
3
5
6
7
8
9
2
10014972
UP
STROKE
DOWN
STROKE
4
ÎÎÎ
ÎÎÎ
ÎÎ
ÎÎ
Figure 2-7 Rhino AB Pump Operation
1. Connecting rod
2. Packing gland
3. Outlet port
4. Solvent chamber
5. Solvent chamber drain port
6. Plunger
7. Pressure ball check
8. Siphon ball check
9. Inlet port