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Econo-Coat r Manual Powder Spray Gun Customer Product Manual Part 1013760E Issued 10/03 NORDSON CORPORATION AMHERST, OHIO USA For parts and technical support, call the Industrial Coating Systems Customer Support Center at (800) 433-9319 or contact your local Nordson representative. This document is subject to change without notice. Check http://emanuals.nordson.com for the latest version.

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Page 1: Econo-Coat Manual Powder Spray Gun - Nordsonemanuals.nordson.com/finishing/files/Powder/1013760e.pdf · Econo-Coat Manual Powder Spray Gun 1 2003 Nordson Corporation Part 1013760E

Econo-Coat�Manual Powder Spray Gun

Customer Product ManualPart 1013760E

Issued 10/03

NORDSON CORPORATION AMHERST, OHIO USA

For parts and technical support, call the Industrial CoatingSystems Customer Support Center at (800) 433-9319 or

contact your local Nordson representative.

This document is subject to change without notice.Check http://emanuals.nordson.com for the latest version.

Page 2: Econo-Coat Manual Powder Spray Gun - Nordsonemanuals.nordson.com/finishing/files/Powder/1013760e.pdf · Econo-Coat Manual Powder Spray Gun 1 2003 Nordson Corporation Part 1013760E

Part 1013760E � 2003 Nordson Corporation

Table of ContentsSafety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Qualified Personnel 1. . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Regulations and Approvals 1. . . . . . . . . . . . . . . . . . .Personal Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .Fire Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Grounding 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Action in the Event of a Malfunction 2. . . . . . . . . . .Disposal 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spray Gun Components 3. . . . . . . . . . . . . . . . . . . . .Theory of Operation 5. . . . . . . . . . . . . . . . . . . . . . . . .Specifications 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shutdown 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Daily Maintenance 9. . . . . . . . . . . . . . . . . . . . . . . . . .Periodic Maintenance 9. . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Resistance and Continuity Tests 12. . . . . . . . . . . . . .

Voltage Multiplier and Electrode Assembly Resistance Test 12. . . . . . . .Electrode Assembly Resistance Test 12. . . . . . . .Spray Gun Cable Continuity Tests 13. . . . . . . . . .

Repair 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrode Assembly Replacement 14. . . . . . . . . . . . .Voltage Multiplier Replacement 14. . . . . . . . . . . . . . .Cable Replacement 15. . . . . . . . . . . . . . . . . . . . . . . . .Heat Sink Pad Replacement 16. . . . . . . . . . . . . . . . .

Parts 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using the Illustrated Parts List 17. . . . . . . . . . . . . . . .Spray Gun Parts 18. . . . . . . . . . . . . . . . . . . . . . . . . . .Electrode Assembly 20. . . . . . . . . . . . . . . . . . . . . . . .

Options 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Deflectors 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pattern Adjusters 22. . . . . . . . . . . . . . . . . . . . . . . . . . .Glass-Filled PTFE Flat-Spray Nozzles 23. . . . . . . . .Tivar Flat-Spray Nozzles 23. . . . . . . . . . . . . . . . . . . . .Lance Extensions 24. . . . . . . . . . . . . . . . . . . . . . . . . .Powder and Air Tubing 24. . . . . . . . . . . . . . . . . . . . . .Shorting Plug 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contact UsNordson Corporation welcomes requests for information, comments, andinquiries about its products. General information about Nordson can befound on the Internet using the following address:http://www.nordson.com.Address all correspondence to:

Nordson CorporationAttn: Customer Service555 Jackson StreetAmherst, OH 44001

NoticeThis is a Nordson Corporation publication which is protected by copyright.Original copyright date 2002. No part of this document may bephotocopied, reproduced, or translated to another language without theprior written consent of Nordson Corporation. The information containedin this publication is subject to change without notice.

Trademarks

Cross-Cut, Econo-Coat, Nordson, and the Nordson logo are registeredtrademarks of Nordson Corporation.

Tivar is a registered trademark of Poly-Hi Corporation.

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Econo-Coat Manual Powder Spray Gun 1

Part 1013760E� 2003 Nordson Corporation

Econo-Coat Manual Powder Spray Gun

Safety

Read and follow these safety instructions. Task-and equipment-specific warnings, cautions, andinstructions are included in equipmentdocumentation where appropriate.

Make sure all equipment documentation, includingthese instructions, is accessible to all personsoperating or servicing equipment.

Qualified PersonnelEquipment owners are responsible for making surethat Nordson equipment is installed, operated, andserviced by qualified personnel. Qualifiedpersonnel are those employees or contractors whoare trained to safely perform their assigned tasks.They are familiar with all relevant safety rules andregulations and are physically capable ofperforming their assigned tasks.

Intended UseUse of Nordson equipment in ways other thanthose described in the documentation supplied withthe equipment may result in injury to persons ordamage to property.

Some examples of unintended use of equipmentinclude

� using incompatible materials

� making unauthorized modifications

� removing or bypassing safety guards orinterlocks

� using incompatible or damaged parts

� using unapproved auxiliary equipment

� operating equipment in excess of maximumratings

Regulations and ApprovalsMake sure all equipment is rated and approved forthe environment in which it is used. Any approvalsobtained for Nordson equipment will be voided ifinstructions for installation, operation, and serviceare not followed.

All phases of equipment installation must complywith all federal, state, and local codes.

Personal SafetyTo prevent injury follow these instructions.

� Do not operate or service equipment unless youare qualified.

� Do not operate equipment unless safetyguards, doors, or covers are intact andautomatic interlocks are operating properly. Donot bypass or disarm any safety devices.

� Keep clear of moving equipment. Beforeadjusting or servicing any moving equipment,shut off the power supply and wait until theequipment comes to a complete stop. Lock outpower and secure the equipment to preventunexpected movement.

� Relieve (bleed off) hydraulic and pneumaticpressure before adjusting or servicingpressurized systems or components.Disconnect, lock out, and tag switches beforeservicing electrical equipment.

� Obtain and read Material Safety Data Sheets(MSDS) for all materials used. Follow themanufacturer’s instructions for safe handlingand use of materials, and use recommendedpersonal protection devices.

� To prevent injury, be aware of less-obviousdangers in the workplace that often cannot becompletely eliminated, such as hot surfaces,sharp edges, energized electrical circuits, andmoving parts that cannot be enclosed orotherwise guarded for practical reasons.

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Econo-Coat Manual Powder Spray Gun2

Part 1013760E � 2003 Nordson Corporation

Fire SafetyTo avoid a fire or explosion, follow theseinstructions.

� Do not smoke, weld, grind, or use open flameswhere flammable materials are being used orstored.

� Provide adequate ventilation to preventdangerous concentrations of volatile materialsor vapors. Refer to local codes or your materialMSDS for guidance.

� Do not disconnect live electrical circuits whileworking with flammable materials. Shut offpower at a disconnect switch first to preventsparking.

� Know where emergency stop buttons, shutoffvalves, and fire extinguishers are located. If afire starts in a spray booth, immediately shut offthe spray system and exhaust fans.

� Clean, maintain, test, and repair equipmentaccording to the instructions in your equipmentdocumentation.

� Use only replacement parts that are designedfor use with original equipment. Contact yourNordson representative for parts informationand advice.

Grounding

WARNING: Operating faulty electrostaticequipment is hazardous and can causeelectrocution, fire, or explosion. Makeresistance checks part of your periodicmaintenance program. If you receive evena slight electrical shock or notice staticsparking or arcing, shut down all electricalor electrostatic equipment immediately. Donot restart the equipment until the problemhas been identified and corrected.

All work conducted inside the spray booth or within1 m (3 ft) of booth openings is considered within aClass 2, Division 1 or 2 Hazardous location andmust comply with NFPA 33, NFPA 70 (NEC articles500, 502, and 516), and NFPA 77, latestconditions.

� All electrically conductive objects in the sprayareas shall be electrically connected to groundwith a resistance of not more than 1 megohmas measured with an instrument that applies atleast 500 volts to the circuit being evaluated.

� Equipment to be grounded includes, but is notlimited to, the floor of the spray area, operatorplatforms, hoppers, photoeye supports, andblow-off nozzles. Personnel working in thespray area must be grounded.

� There is a possible ignition potential from thecharged human body. Personnel standing on apainted surface, such as an operator platform,or wearing non-conductive shoes, are notgrounded. Personnel must wear shoes withconductive soles or use a ground strap tomaintain a connection to ground when workingwith or around electrostatic equipment.

� Operators must maintain skin-to-handle contactbetween their hand and the gun handle toprevent shocks while operating manualelectrostatic spray guns. If gloves must beworn, cut away the palm or fingers, wearelectrically conductive gloves, or wear agrounding strap connected to the gun handle orother true earth ground.

� Shut off electrostatic power supplies andground gun electrodes before makingadjustments or cleaning powder spray guns.

� Connect all disconnected equipment, groundcables, and wires after servicing equipment.

Action in the Event of aMalfunctionIf a system or any equipment in a systemmalfunctions, shut off the system immediately andperform the following steps:

� Disconnect and lock out electrical power. Closepneumatic shutoff valves and relieve pressures.

� Identify the reason for the malfunction andcorrect it before restarting the equipment.

DisposalDispose of equipment and materials used inoperation and servicing according to local codes.

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Econo-Coat Manual Powder Spray Gun 3

Part 1013760E� 2003 Nordson Corporation

Description The Econo-Coat manual powder spray gunelectrostatically charges and sprays organicpowder coatings. The integral power supply (IPS)voltage multiplier is user-replaceable.

NOTE: The spray gun should be used only withthe Econo-Coat manual powder spray gun controlunit.

Spray Gun ComponentsRefer to Table 1 for a description of the spray gun’smajor components.

See Figure 1.

Table 1 Spray Gun Components

Item Description Function

1 Storage Hook Allows the spray gun to be safely hung for storage

2 Voltage Multiplier Converts the control unit’s low-voltage power to highelectrostatic voltage

3 Electrode Assembly Uses the electrostatic voltage produced by the voltagemultiplier to charge the powder being sprayed

4 Nozzle

NOTE: Standard conicalnozzle is shown. Othernozzles are available. Referto Options on page 21 foroptional nozzles and orderinginformation.

Shapes the pattern of the spray as it exits the spray gun

With the conical nozzle shown, the pattern adjuster (4a)may be slid toward or away from the deflector (4b) tomodify the spray pattern

� To create a narrower spray pattern, slide the patternadjuster toward the deflector

� To create a wider spray pattern, slide the patternadjuster away from the deflector

5 Inlet Adapter Connects the powder feed hose to the spray gun

6 Trigger Activates the spray gun, sending charged powder out ofthe nozzle

7 Cable Supplies power to the spray gun and relays current andfeedback information to the control unit

NOTE: An optional 4-meter extension cable is available.Refer to Spray Gun Parts on page 18 for orderinginformation.

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Econo-Coat Manual Powder Spray Gun4

Part 1013760E � 2003 Nordson Corporation

Description (contd)

1400066A

21

7

65

3

4

4a 4b

Figure 1 Spray Gun Components

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Econo-Coat Manual Powder Spray Gun 5

Part 1013760E� 2003 Nordson Corporation

Theory of OperationSee Figure 1.

When the operator pulls the trigger (6), the voltagemultiplier (2) generates an electrostatic field aroundthe electrode in the spray gun’s nozzle (4).

The spray gun’s control unit sends compressed airthrough the powder pump, which draws fluidizedpowder up the pickup tube, through the powderfeed hose, and into the spray gun.

When the powder reaches the spray gun, thepowder flows into the inlet adapter (5); around theelectrode assembly (3), where the powder iselectrostatically charged; and out the nozzle. Thecharged powder is then attracted to grounded partsin the spray booth.

Powder coatings typically are fluidized in one of twoways:

Feed Hopper: Powder is placed in a hopper,which has a porous membrane called a fluidizingplate at the bottom of the hopper. The powder inthe hopper is fluidized when compressed air isforced through the fluidizing plate.

Vibratory Box Feeder: A box of powder is placedon the vibratory box feeder, which vibrates the boxto maintain even distribution of powder in the box.The powder in the box is fluidized whencompressed air is introduced at the bottom of thepump’s pickup tube.

SpecificationsNOTE: Because of continuous technologicalimprovements, specifications are subject to changewithout notice.

Table 2 Spray Gun Specifications

Air Pressures

Flow Rate 2 bar (30 psi)

Atomizing 0.7 bar (10 psi)

Electrical Requirements

Voltage Output 95 kV maximum

Current Output 100 A maximum

NOTE: Supply air must be clean and dry. Use aregenerative desiccant or refrigerated air dryercapable of producing a 3.4 �C (38 �F) or lowerdewpoint at the maximum input air pressure. Use afilter system with prefilters and coalescent-typefilters capable of removing oil, water, and dirt in thesubmicron range.

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Part 1013760E � 2003 Nordson Corporation

Connections WARNING: Allow only qualified personnelto perform the following tasks. Follow thesafety instructions in this document and allother related documentation.

See Figure 2.

Refer to Table 3 for a description of the connectionsrequired to install the Econo-Coat manual powderspray gun.

If your spray gun is part of a mobile powder spraysystem, refer to the installation instructionsprovided with the system. The installationinstructions included in this manual are for installinga standalone spray gun.

NOTE: Refer to your control unit and powderpump manuals for more detailed installationinstructions.

Table 3 Connections

Item Description Size Control Unit BackPanel Connection

Other EquipmentConnection

1 Ground Wire — True Earth Ground

2Fluidizing Air Tubing(Blue) 10-mm OD

Fluidizing AirElbow Fitting

3 Atomizing Air Tubing(Blue) 8-mm OD Powder Pump

Connector A

4 Flow Rate Air Tubing(Black) 8-mm OD Powder Pump

Connector F

5 Feed Hose 12.7-mm(1/2-in.) ID

(not connected tocontrol unit)

Powder Pump Outlet;Spray Gun Inlet

6 Spray Gun Cable — GUN OUTPUT(See Note)

Spray Gun Handle(prewired)

7 POWER INPUT Cable — POWER INPUT(prewired) Main Power Supply

8 Air Supply Tubing(Blue) 10-mm OD

IN0−100 PSI0−7 BAR

Main Air Supply

NOTE: Tighten the gun cable retaining nut to 6 N�m (4.4 ft-lb). An optional 4-meter extension cable isavailable. Do not add more than two extension cables to the gun cable.

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Econo-Coat Manual Powder Spray Gun 7

Part 1013760E� 2003 Nordson Corporation

1400073D

A

8

1

2

3

4

C

5

6

7D

B

Tighten to6 N�m (4.4 ft−lb)

Figure 2 Connections

A. Control unitB. Powder pumpC. HopperD. Spray gun

1. Ground wire2. Blue, 10-mm air tubing (fluidizing)3. Blue, 8-mm air tubing (atomizing)4. Black, 8-mm air tubing (flow rate)

5. Feed hose6. Gun cable7. POWER INPUT cable8. Blue, 10-mm air tubing (IN)

Note: Typical powder pump and hopper shown. Connections for a vibratory box feeder system are different than thoseshown. Refer to the Econo-Coat Mobile Powder Spray System with Box Feeder instructions for box feederconnections.

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Econo-Coat Manual Powder Spray Gun8

Part 1013760E � 2003 Nordson Corporation

Operation

WARNING: Allow only qualified personnelto perform the following tasks. Follow thesafety instructions in this document and allother related documentation.

WARNING: This equipment can bedangerous unless it is used in accordancewith the rules laid down in this manual.

WARNING: This apparatus shall be usedonly in spraying areas according toEN 50177 or under equivalent conditions.

WARNING: Do not operate the spray gunif the resistance of the multiplier orelectrode assembly are not within theranges specified in this manual. Failure toobserve this warning may result in personalinjury, fire, or property damage.

WARNING: All conductive equipment inthe spray area must be connected to a trueearth ground. Failure to observe thiswarning may result in a severe shock.

StartupMake sure that the following conditions have beenmet before operating the Econo-Coat manualpowder spray gun:

� All of the Connections on page 6 have beencompleted.

� The air supply system’s filters and dryer areworking properly.

� The booth exhaust fans are operating.

� The powder recovery system is operating.

1. Set the kV and fluidizing and pump airpressures as described in the Operation sectionof the control unit manual.

2. Point the spray gun into the spray booth andpull the trigger.

3. Modify the spray pattern as desired.

See Figure 1.

� For a narrower spray pattern, slide thenozzle’s pattern adjuster (4a) toward thedeflector (4b).

� For a wider spray pattern, slide the nozzle’spattern adjuster (4a) away from thedeflector (4b).

NOTE: Refer to the Operation section of thecontrol unit manual for kV and air pressureadjustments.

Shutdown1. Turn the power switch on the control unit to the

off position.

2. Set all air pressures to zero and relieve systemair pressure.

3. Ground the spray gun electrode to dischargeany residual voltage.

4. Perform the Daily Maintenance procedure onpage 9.

Maintenance

WARNING: Allow only qualified personnelto perform the following tasks. Follow thesafety instructions in this document and allother related documentation.

WARNING: Turn off the gun control unitand disconnect the system from its powersource before performing any of thefollowing tasks. Failure to observe thiswarning may result in a severe shock.

WARNING: Relieve system air pressureand disconnect the system from its input airsupply before performing any of thefollowing tasks. Failure to observe thiswarning may result in personal injury.

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Econo-Coat Manual Powder Spray Gun 9

Part 1013760E� 2003 Nordson Corporation

Daily MaintenanceUse the following procedure to clean the spray gun.

See Figure 3.

NOTE: If necessary, remove any O-rings andclean parts using a cloth dampened with isopropylor ethyl alcohol. Do not immerse the parts inalcohol. Do not use any other solvents.

CAUTION: Carefully remove any fusedpowder from parts using a wooden orplastic dowel or similar tool. Do not usetools that will scratch the plastic. Powderwill build up and impact fuse on anyscratches.

1. Turn off the control unit and disconnect thesystem from its input power source.

2. Relieve system air pressure and disconnect thesystem from its input air supply.

3. Disconnect the powder feed hose (6) from thepump.

4. Point the spray gun into the booth and blow outthe powder from the spray gun and powderfeed hose using low-pressure, compressed air.

5. Remove the nozzle parts (3).

6. Disconnect the powder feed hose and removethe inlet adapter (5).

7. Loosen the set screw (4) and pull the body (2)straight away from the spray gun until the bodyclears the electrode assembly (1). Be carefulnot to damage the electrode assembly whileremoving the body.

8. Clean all parts with low-pressure, compressedair.

9. Inspect all O-rings and replace any that aredamaged.

Periodic Maintenance

Perform the Resistance and Continuity Tests onpages 12−13.

1400056A

2

1

5 4

6

3

Figure 3 Daily Maintenance

1. Electrode assembly2. Body

3. Nozzle parts4. Set screw

5. Inlet adapter6. Powder feed hose

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Econo-Coat Manual Powder Spray Gun10

Part 1013760E � 2003 Nordson Corporation

Troubleshooting WARNING: Allow only qualified personnelto perform the following tasks. Follow thesafety instructions in this document and allother related documentation.

This section contains troubleshooting procedures.These procedures cover only the most commonproblems that you may encounter. If you cannotsolve the problem with the information given here,contact your local Nordson representative for help.

Problem Possible Cause Corrective Action

1. Uneven spray pattern;unsteady orinadequate powderflow

Blockage in spray gun, feed hose,or pump

Perform the Daily Maintenanceprocedure on page 9.

Replace the feed hose if it is cloggedwith fused powder.

Disassemble and clean the pump.

Poor fluidization of powder inhopper

Increase the fluidizing air pressure.

Hopper Systems: Remove thepowder from the hopper. Clean orreplace the fluidizing plate if it iscontaminated.

Box Feeder Systems: Replace thefluidizing disk insert at the end of thepickup tube. Refer to your mobilepowder spray system instructions.

Moisture in powder Check the powder supply, air filters,and dryer.

Replace the powder supply if it iscontaminated.

Worn nozzle Remove, clean, and inspect thenozzle. Replace the nozzle ifnecessary.

If excessive wear or impact fusion ispresent, reduce the flow rate andatomizing air pressures.

Low atomizing or flow rate airpressure

Increase the atomizing and/or flowrate air pressures.

Continued...

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Econo-Coat Manual Powder Spray Gun 11

Part 1013760E� 2003 Nordson Corporation

Problem Possible Cause Corrective Action

2. Loss of wrap; poortransfer efficiency

Low electrostatic voltage Increase the electrostatic voltage.

Poor electrode connection Perform the Voltage Multiplier andElectrode Assembly Resistance Teston page 12.

Poorly grounded parts Check the part hangers for powderbuildup. The resistance between theparts and the ground must be1 megohm or less. For best results,the resistance should be 500 ohms orless.

3. No kV output from thespray gun

Damaged spray gun cable Perform the Spray Gun CableContinuity Tests on page 13. If anopen or short circuit is found, replacethe cable.

Malfunctioning trigger switch With the trigger switch actuated,check for continuity betweenpins 1 and 2 of the control unit end ofthe gun cable. If there is nocontinuity, replace the cable.

Malfunctioning voltage multiplier Perform the Voltage Multiplier andElectrode Assembly Resistance Teston page 12.

Poor electrode connection Perform the Voltage Multiplier andElectrode Assembly Resistance Teston page 12.

Malfunctioning control unit Unplug the gun end of the cable fromthe voltage multiplier. With the triggerswitch actuated, check for 21 Vdcbetween pins 2 and 3 of the gun endof the gun cable. If the reading is not21 Vdc, contact your Nordsonrepresentative.

4. No kV output and nopowder output

Malfunctioning trigger switch orcable

With the switch actuated, check forcontinuity between pins 1 and 2 of thecontrol unit end of the cable.

If no short or open circuit is found inthe trigger switch, check thecontinuity across the cable.

If no continuity is found across thecable, replace the cable.

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Econo-Coat Manual Powder Spray Gun12

Part 1013760E � 2003 Nordson Corporation

Resistance and Continuity Tests

WARNING: Turn off the spray gun control unit and ground the gun electrode before performing thefollowing tasks. Failure to observe this warning could result in a severe shock.

Voltage Multiplier and ElectrodeAssembly Resistance Test

See Figure 4.

1. Disassemble and clean the spray gun’s powderpath. Refer to the Daily Maintenanceprocedure on page 9 for instructions.

2. Remove the three screws securing the halvesof the spray gun handle. Separate the handlesto access the electrostatic components.

3. Disconnect the cable connector from thevoltage multiplier and remove the multiplier (3)and electrode assembly (4) from the spray gun.

4. Connect the shorting plug (1) to the voltagemultiplier connector (2).

5. Connect a megohmmeter’s (6) probes to theelectrode (5) and shorting plug ring-tongterminal. If the reading is infinite, switch theprobes.

6. The megohmmeter should read between 140and 210 megohms at 500 volts. If the readingis not in this range, perform the ElectrodeAssembly Resistance Test.

7. Replace any parts that have burn-through holesor arc tracks.

NOTE: When you have completed the resistancetests, install a new heat sink pad on the gun hookbefore you assemble the spray gun. Refer to HeatSink Pad Replacement on page 16.

Electrode Assembly Resistance Test

See Figure 5.

1. Perform the Voltage Multiplier and ElectrodeAssembly Resistance Test.

2. Unscrew the electrode assembly (2) from thevoltage multiplier.

3. Connect the megohmmeter’s probes to theelectrode (1) and the contact pin (3).

4. The megohmmeter should read between 2 and10 megohms at 500 volts. If the reading is notin this range, replace the electrode assembly.

1400068A

12

3

4

5

6

Figure 4 Voltage Multiplier and Electrode AssemblyResistance Test

1. Shorting plug2. Multiplier connector3. Multiplier assembly

4. Electrode assembly5. Electrode6. Megohmmeter

1400069A

1

2

3

Figure 5 Electrode Assembly Resistance Test

1. Electrode2. Electrode assembly

3. Contact pin

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Econo-Coat Manual Powder Spray Gun 13

Part 1013760E� 2003 Nordson Corporation

Spray Gun Cable Continuity TestsSee Figure 6.

Pin Functions

Refer to Table 4 and see Figure 6 for the functionsof the cable pins.

Table 4 Control Unit End Pin Functions

Control Unit End

Pin Function

1 Trigger

2 Common

3 + Vdc

4 A Feedback

5 Blank

6 Ground

Multiplier End

Pin Function

1 + Vdc

2 A Feedback

3 Common

Trigger Switch

Pin Function

1 Trigger

2 Common

3 Not Connected

Control Unit End to Multiplier End ContinuityTest

Refer to Table 5 and see Figure 6 for a list ofcontinuity tests to perform between the control unitend and the voltage multiplier end.

Table 5 Control Unit End to Multiplier EndContinuity Test

Control Unit End Pin Multiplier End Pin

3 1

4 2

Control Unit End to Trigger Switch ContinuityTest

See Figure 6.

While the trigger is pulled, test for continuitybetween pins 1 and 2 of the control unit end of thecable.

1400057ACONTROL UNIT END

12

3

45

6 12

3

MULTIPLIER END

TRIGGER SWITCH

Figure 6 Spray Gun Cable Pins

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Econo-Coat Manual Powder Spray Gun14

Part 1013760E � 2003 Nordson Corporation

Repair WARNING: Allow only qualified personnelto perform the following tasks. Follow thesafety instructions in this document and allother related documentation.

WARNING: Turn off the control unit anddisconnect the system from its input powersource before performing any of thefollowing tasks. Failure to observe thiswarning may result in a severe shock.

WARNING: Relieve system air pressureand disconnect the system from its input airsupply before performing any of thefollowing tasks. Failure to observe thiswarning may result in personal injury.

Electrode Assembly ReplacementSee Figure 7.

1. Turn off the control unit and disconnect thesystem from its input power source.

2. Relieve system air pressure and disconnect thesystem from its input air supply.

3. Disconnect the spray gun cable from the controlunit.

4. Disconnect the powder feed hose and removethe inlet adapter (5) from the spray gun.

5. Pull the nozzle parts (3) straight off the spraygun.

6. Loosen the set screw (4) and pull the body (2)straight off the spray gun until the body clearsthe electrode assembly (9). Be careful not todamage the electrode assembly.

7. Grasp the electrode assembly near the spraygun and unscrew it from the voltagemultiplier (8).

8. Follow steps 3−7 in reverse to install the newelectrode assembly.

Voltage Multiplier Replacement See Figure 7.

1. Perform steps 1−7 of the Electrode AssemblyReplacement procedure.

2. Remove the three screws (17) and the righthandle (16).

3. Disconnect the cable connector (7) and removethe extension (1) and voltage multiplier (8) fromthe left handle (6).

4. Replace the heat sink pad (18). Refer to HeatSink Pad Replacement on page 16 forinstructions.

5. Connect the cable connector to the new voltagemultiplier and install the voltage multiplier intothe extension.

NOTE: When assembling the handles andextension, make sure that the pins on the side ofthe extension are aligned with the appropriatespace in each handle.

6. Carefully set the voltage multiplier andextension into the left handle. Secure the righthandle to the left handle using the screws.

7. Perform the Electrode Assembly Replacementprocedure in reverse to install the electrodeassembly.

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Econo-Coat Manual Powder Spray Gun 15

Part 1013760E� 2003 Nordson Corporation

Cable ReplacementSee Figure 7.

1. Perform steps 1−7 of the Electrode AssemblyReplacement procedure.

2. Remove the screw (14) and the hosebracket (13).

3. Remove the three screws (17) and the righthandle (16).

4. Disconnect the cable connector (7) and removethe extension (1) and voltage multiplier (8) fromthe left handle.

NOTE: Do not lose the trigger actuator (10) whenyou remove the trigger switch.

5. Remove the two screws (12) and the triggerswitch (11).

6. Lift the cable out of the left handle (6).

NOTE: Before you install the multiplier, install anew heat sink pad (18). Refer to Heat Sink PadReplacement on page 16 for instructions.

7. Install a new cable by following steps 1−6 inreverse.

1400060B

1

2

8

9

1314

54

1217

6

12

15

7

3

1011

16

18

Figure 7 Spray Gun Repair

1. Extension2. Body3. Nozzle4. Set screw5. Inlet adapter6. Left handle

7. Cable connector8. Voltage multiplier9. Electrode assembly

10. Trigger actuator11. Trigger switch12. Screws (2)

13. Hose bracket14. Screw with integral lock

washer15. Cable base16. Right handle17. Screws (3)18. Heat sink pad

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Econo-Coat Manual Powder Spray Gun16

Part 1013760E � 2003 Nordson Corporation

Heat Sink Pad Replacement Install a new heat sink pad each time that youremove the multiplier from the spray gun.

1. Remove the multiplier from the spray gun.Refer to Voltage Multiplier Replacement onpage 14 for instructions.

2. Remove the hook from the left handle.

3. See Figure 8. Remove the old heat sinkpad (2) from the hook (1). Remove anyremaining adhesive from the hook using a razorblade and a cloth dampened with isopropylalcohol.

4. Peel the plastic liner off one side of the newheat sink pad.

5. Place the heat sink pad on the bottom of thehook, making sure that the edge of the pad isflush with the front edge of the hook.

6. Remove the plastic liner from the bottom of thenew heat sink pad.

7. Install the hook into the left handle andassemble the spray gun.

1401346A

1

2

Figure 8 Heat Sink Pad Replacement

1. Hook2. Heat sink pad

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Econo-Coat Manual Powder Spray Gun 17

Part 1013760E� 2003 Nordson Corporation

Parts

To order parts, call the Nordson Customer ServiceCenter or your local Nordson representative. Usethis five-column parts list, and the accompanyingillustration, to describe and locate parts correctly.

Using the Illustrated Parts ListNumbers in the Item column correspond tonumbers that identify parts in illustrations followingeach parts list. The code NS (not shown) indicatesthat a listed part is not illustrated. A dash (—) isused when the part number applies to all parts inthe illustration.

The number in the Part column is the NordsonCorporation part number. A series of dashes in thiscolumn (- - - - - -) means the part cannot beordered separately.

The Description column gives the part name, aswell as its dimensions and other characteristicswhen appropriate. Indentions show therelationships between assemblies, subassemblies,and parts.

� If you order the assembly, items 1 and 2 will beincluded.

� If you order item 1, item 2 will be included.

� If you order item 2, you will receive item 2 only.

The number in the Quantity column is the quantityrequired per unit, assembly, or subassembly. Thecode AR (As Required) is used if the part number isa bulk item ordered in quantities or if the quantityper assembly depends on the product version ormodel.

Letters in the Note column refer to notes at the endof each parts list. Notes contain importantinformation about usage and ordering. Specialattention should be given to notes.

Item Part Description Quantity Note— 0000000 Assembly 11 000000 � Subassembly 2 A2 000000 � � Part 1

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Econo-Coat Manual Powder Spray Gun18

Part 1013760E � 2003 Nordson Corporation

Spray Gun Parts See Figure 9.

Item Part Description Quantity Note— 1008645 HANDGUN, Econo-Coat 11 1003337 � EXTENSION, handgun 12 940243 � O-RING, silicone, 1.125 x 1.250 x 0.063 in. 13 1003336 � BODY, handgun 14 940182 � O-RING, silicone, 0.750 x 0.875 x 0.063 in. 25 309445 � NOZZLE, conical, 26 mm, with O-rings 16 309450 � � PATTERN ADJUSTER, 26 mm deflector,

with O-ring1

7 941224 � � � O-RING, silicone, 1.125 x 1.312 x 0.094 in. 18 309448 � � NOZZLE, conical, 26 mm, with O-ring 19 940212 � � � O-RING, silicone, 0.938 x 1.063 x 0.063 in. 110 173141 � DEFLECTOR, 26 mm, flat, Tivar, with O-ring 111 940084 � � O-RING, silicone, 0.188 x 0.312 x 0.063 in. 112 982539 � SCREW, slotted, M6 x 6, nylon, black 113 134386 � ADAPTER, hose, with O-ring, universal 114 - - - - - - � � ADAPTER, hose 115 940163 � � O-RING, silicone, 0.625 x 0.750 x 0.063 in. 116 - - - - - - � HOOK, handgun 117 1032181 � KIT, Econo-Coat handgun handle 118 - - - - - - � � HANDLE, left, handgun 119 - - - - - - � � HANDLE, right, handgun 120 982064 � � SCREW, oval head, slotted, M4 x 12, zinc 321 132334 � PIVOT, trigger 122 133783 � SPRING, trigger, return 123 125617 � TRIGGER, handgun, modular 124 982370 � SCREW, pan head, slotted, M2 x 5, zinc 125 1001202 � CABLE, handgun 126 982847 � SCREW, pan head, recessed, M4 x 10, with

lock washer1

27 132345 � BRACKET, cable/tube, retaining 128 803210 � SCREW, pan head, #2-56 x 0.500 in. long 229 983113 � WASHER, lock, e, split, 2, slotted, zinc 230 983510 � WASHER, flat, e, 0.94 x 0.188 x 0.025 in. 231 132336 � ACTUATOR, switch 132 288552 � MULTIPLIER, 95 kV, negative 133 1013629 � ELECTRODE ASSEMBLY, handgun, packaged 1 A34 1045722 � SERVICE KIT, heat sink pad 1 BNS 302103 � NOZZLE, flat spray, 4 mm 135 1036142 CABLE, handgun, 4-meter extension 1 C

NOTE A: Refer to Electrode Assembly on page 20 for a breakdown of the parts included in this assembly.

B: Order this kit to replace the heat sink pad each time that the multiplier is removed from the spray gun.

C: Optional extension cable. Do not add more than two extension cables to the gun cable.

NS: Not Shown

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Econo-Coat Manual Powder Spray Gun 19

Part 1013760E� 2003 Nordson Corporation

1400065E

1

3

8

4

18

3233

2322

20

28

31

2726

25

14

12

16

21

2

24

15

9

7

6

11

2930

5

10

13

19

17

35

34

Figure 9 Spray Gun Parts

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Econo-Coat Manual Powder Spray Gun20

Part 1013760E � 2003 Nordson Corporation

Electrode Assembly See Figure 10.

Item Part Description Quantity Note— 1013629 ELECTRODE ASSEMBLY, handgun, packaged 11 1005060 � SUPPORT, electrode, handgun 12 941081 � O-RING, silicone, 0.250 x 0.438 x 0.094 in. 13 940182 � O-RING, silicone, 0.750 x 0.875 x 0.063 in. 14 - - - - - - � CABLE, core 15 1005061 � SLEEVE, wear, handgun 16 288554 � HOLDER, cable, electrode 17 288560 � ELECTRODE, spring, contact 1

1400306A

12

3 4 5 67

Figure 10 Electrode Assembly Parts

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Econo-Coat Manual Powder Spray Gun 21

Part 1013760E� 2003 Nordson Corporation

Options

This section includes optional equipment availablefor the Econo-Coat manual powder spray gun.Contact your Nordson representative for orderinginformation.

DeflectorsSee Figure 11.

Item Part Description Quantity Note1 135865 14-mm deflector, Tivar, with O-ring 11 147880 16-mm deflector, Tivar, with O-ring 11 173138 19-mm deflector, Tivar, with O-ring 12 173141 26-mm deflector, Tivar, with O-ring 12 249233 38-mm deflector, Tivar, with O-ring 13 940084 � O-RING, silicone, 0.188 x 0.312 x 0.063 in. 1 A

NOTE A: This O-ring is included with all deflectors.

1400259A

3

1 2

3

mm mm

Figure 11 Deflectors

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Econo-Coat Manual Powder Spray Gun22

Part 1013760E � 2003 Nordson Corporation

Pattern AdjustersSee Figure 12.

Item Part Description Quantity Note1 309444 19-mm pattern adjuster 1 A1 309450 26-mm pattern adjuster 1 B2 309446 38-mm pattern adjuster 1 C

NOTE A: This pattern adjuster can be used with 14-, 16-, and 19-mm deflectors.

B: This pattern adjuster can only be used with a 26-mm deflector.

C: This pattern adjuster can only be used with a 38-mm deflector.

1400260A

1 2

Figure 12 Pattern Adjusters

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Econo-Coat Manual Powder Spray Gun 23

Part 1013760E� 2003 Nordson Corporation

Glass-Filled PTFE Flat-SprayNozzlesSee Figure 13.

Item Part Description Quantity Note1 302108 2.5-mm flat-spray nozzle, glass-filled PTFE 11 302109 3-mm flat-spray nozzle, glass-filled PTFE 11 302110 4-mm flat-spray nozzle, glass-filled PTFE 11 302111 6-mm flat-spray nozzle, glass-filled PTFE 1

Tivar Flat-Spray NozzlesSee Figure 13.

Item Part Description Quantity Note1 302101 2.5-mm flat-spray nozzle, Tivar 11 302102 3-mm flat-spray nozzle, Tivar 11 302104 6-mm flat-spray nozzle, Tivar 12 302105 60� Cross-Cut nozzle, 2.5-mm slot, Tivar 13 302106 90� Cross-Cut nozzle, 2.5-mm slot, Tivar 14 302107 CASTLE nozzle, 2.5-mm slot, Tivar 1

1400261A

1 2 3 4

Figure 13 Flat-Spray Nozzles

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Econo-Coat Manual Powder Spray Gun24

Part 1013760E � 2003 Nordson Corporation

Lance Extensions Part Description Note

305799 150-mm LANCE EXTENSION305800 300-mm LANCE EXTENSION

Powder and Air TubingOrder tubing in increments of 1 foot.

Part Description Note900740 AIR TUBING, 10-mm OD, black, polyurethane900618 AIR TUBING, 8-mm OD, blue, polyurethane900619 AIR TUBING, 8-mm OD, black, polyurethane900650 POWDER TUBING, 12.7-mm (1/2-in.) ID blue900648 POWDER TUBING, 11-mm ID, blue A900649 POWDER TUBING, 9.5-mm (3/8-in.) ID, blue A

NOTE A: These optional powder feed hose sizes may improve powder flow and pattern, depending on yourapplication.

Shorting PlugSee Figure 14.

Use this shorting plug to perform the Resistanceand Continuity Tests described in Troubleshooting.

Item Part Description Quantity Note1 161411 PLUG, shorting, IPS 1

1400262A

1

Figure 14 Shorting Plug