sure coat automatic powder spray gun -...

Sure Coat� Automatic Powder Spray Gun

Customer Product ManualPart 334627−05

Issued 04/15

NORDSON CORPORATION AMHERST, OHIO USA

For parts and technical support, call the Finishing Customer Support Center at (800) 433-9319.

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

Part 334627−05 � 2015 Nordson Corporation

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 Service300 Nordson DriveAmherst, OH 44001

NoticeThis is a Nordson Corporation publication which is protected by copyright.Original copyright date 2000. 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

Nordson, the Nordson logo, and Sure Coat are registered trademarks ofNordson Corporation.

All other trademarks are the property of their respective owners.

Change Record i

Part 334627−05� 2015 Nordson Corporation

Change RecordRevision Date Change

J03 6/09 Electrode support part number changed from 1010752 to 1093572.

3 ft. tube gun obsoleted, removed part number.

04 6/14 Removed CE, ATEX, and zoning information and labels no longerapplicable.

05 4/15 Marked spray gun assemblies as obsolete and added gun body servicekits.

Change Recordii


Table of Contents iii


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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fire Safety 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Grounding 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Action in the Event of a Malfunction 1-3. . . . . . . . . . . . . . . . . . . . . . . .Disposal 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Features 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mounting Configurations 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Theory of Operation 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Output 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Pressure Requirements 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Quality Requirements 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Rating 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Special Conditions for Safe Use 2-4. . . . . . . . . . . . . . . . . . . . . . . . .Dimensions 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mounting 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tube-Mount Gun Mounting 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Types of Tube-Mounting Assemblies 3-1. . . . . . . . . . . . . . . . . . .Installing Tube-Mounting Assemblies 3-2. . . . . . . . . . . . . . . . . .Adjusting the Tube-Mounting Assemblies 3-2. . . . . . . . . . . . . . .

Bar-Mount Gun Mounting 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connections 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powder Feed Hose Installation 3-5. . . . . . . . . . . . . . . . . . . . . . . . . .Gun Cable and Air Tubing Installation 3-7. . . . . . . . . . . . . . . . . . . .

Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Startup 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Quick Color Change 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shutdown 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Maintenance 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Weekly Maintenance 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsiv


Troubleshooting 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting Charts 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Continuity and Resistance Checks 5-3. . . . . . . . . . . . . . . . . . . . . . . . .

Gun Resistance Check 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Multiplier Assembly Resistance Checks 5-4. . . . . . . . . . . . . . . . . .

Multiplier and Contact Tip Assembly Resistance Check 5-4. .Multiplier Resistance Check 5-5. . . . . . . . . . . . . . . . . . . . . . . . . .Contact Tip Resistance Check 5-5. . . . . . . . . . . . . . . . . . . . . . . .

Electrode Support Assembly Continuity Check 5-6. . . . . . . . . . . .Gun Cable Continuity Checks 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . .

Cable Pin Functions 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Across the Cable Continuity Checks 5-8. . . . . . . . . . . . . . . . . . .Control Unit End Resistance and Continuity Checks 5-8. . . . .

Repair 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Powder Path Repair 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembling the Powder Path 6-1. . . . . . . . . . . . . . . . . . . . . . . . .Inspecting and Cleaning the Powder Path 6-2. . . . . . . . . . . . . . . . .Assembling the Powder Path 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal from the Gun Mount 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tube-Mount Gun Removal 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bar-Mount Gun Removal 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Multiplier Replacement 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tube-Mount Gun Multiplier Replacement 6-6. . . . . . . . . . . . . . . . .

Removing the Multiplier from the Tube-Mount Gun 6-6. . . . . . .Installing the Multiplier in the Tube-Mount Gun 6-6. . . . . . . . . .

Bar-Mount Gun Multiplier Replacement 6-8. . . . . . . . . . . . . . . . . . .Removing the Multiplier from the Bar-Mount Gun 6-8. . . . . . . .Installing the Multiplier in the Bar-Mount Gun 6-8. . . . . . . . . . . .

Parts 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List 7-1. . . . . . . . . . . . . . . . . . . . . . . . . .Spray Gun Parts 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spray Gun Assemblies 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tube-Mount Gun Parts 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bar-Mount Gun Parts 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gun Body Service Kits 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mounting Assemblies 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tube-Mount Gun Mounting Assemblies 7-8. . . . . . . . . . . . . . . . . . .Standard Gun Bar Assembly for Tube-Mount Guns 7-8. . . . . .Pivoting Gun Bar Assembly for Tube-Mount Guns 7-9. . . . . . .Extrusion Gun Mount Assembly for Tube-Mount Guns 7-10. . .

Bar-Mount Gun Mounting Assemblies 7-11. . . . . . . . . . . . . . . . . . . .3-ft Gun Bar Assembly 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-ft Gun Bar Assembly 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Powder Feed Hose Support Bracket Kit 7-12. . . . . . . . . . . . . . . .

Service Kits 7-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cable Kits 7-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hose Connector Kits 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-mm Hose Connector Kit 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . .1/2-in. Hose Connector Kit 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . .

O-ring Service Kit 7-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents v


Options 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Options List 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Quick-Disconnect Fittings and Components 8-2. . . . . . . . . . . . . . . . .

Quick-Disconnect Parts 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Quick-Disconnect Fitting Installation 8-3. . . . . . . . . . . . . . . . . . . . .

Removing Standard Fittings 8-3. . . . . . . . . . . . . . . . . . . . . . . . . .Installing Quick-Disconnect Fittings 8-3. . . . . . . . . . . . . . . . . . .Using the Quick-Disconnect Fittings 8-3. . . . . . . . . . . . . . . . . . .

90-Degree Spray Extension 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional Nozzles 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45-Degree Corner-Spray Nozzle 8-6. . . . . . . . . . . . . . . . . . . . . . . . .45-Degree In-Line Flat-Spray Nozzle 8-6. . . . . . . . . . . . . . . . . . . .9-mm Open Nozzle 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-Degree Conical Nozzle 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flat Spray Nozzles 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ion Collector Kits 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tube-Mount Gun Ion Collector Kit 8-8. . . . . . . . . . . . . . . . . . . . . . .Bar-Mount Gun Ion Collector Kit 8-8. . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsvi


Safety 1-1


Section 1Safety

Introduction Read and follow these safety instructions. Task- and equipment-specificwarnings, cautions, and instructions are included in equipmentdocumentation where appropriate.

Make sure all equipment documentation, including these instructions, isaccessible to all persons operating or servicing equipment.

Qualified Personnel Equipment owners are responsible for making sure that Nordson equipmentis installed, operated, and serviced by qualified personnel. Qualifiedpersonnel are those employees or contractors who are trained to safelyperform their assigned tasks. They are familiar with all relevant safety rulesand regulations and are physically capable of performing their assignedtasks.

Intended Use Use of Nordson equipment in ways other than those described in thedocumentation supplied with the equipment may result in injury to personsor damage to property.

Some examples of unintended use of equipment include

� using incompatible materials

� making unauthorized modifications

� removing or bypassing safety guards or interlocks

� using incompatible or damaged parts

� using unapproved auxiliary equipment

� operating equipment in excess of maximum ratings

Regulations and Approvals Make sure all equipment is rated and approved for the environment in whichit is used. Any approvals obtained for Nordson equipment will be voided ifinstructions for installation, operation, and service are not followed.

All phases of equipment installation must comply with all federal, state, andlocal codes.

Safety1-2


Personal Safety To prevent injury follow these instructions.

� Do not operate or service equipment unless you are qualified.

� Do not operate equipment unless safety guards, doors, or covers areintact and automatic interlocks are operating properly. Do not bypass ordisarm any safety devices.

� Keep clear of moving equipment. Before adjusting or servicing anymoving equipment, shut off the power supply and wait until theequipment comes to a complete stop. Lock out power and secure theequipment to prevent unexpected movement.

� Relieve (bleed off) hydraulic and pneumatic pressure before adjusting orservicing pressurized systems or components. Disconnect, lock out,and tag switches before servicing electrical equipment.

� Obtain and read Material Safety Data Sheets (MSDS) for all materialsused. Follow the manufacturer’s instructions for safe handling and useof materials, and use recommended personal protection devices.

� To prevent injury, be aware of less-obvious dangers in the workplacethat often cannot be completely eliminated, such as hot surfaces, sharpedges, energized electrical circuits, and moving parts that cannot beenclosed or otherwise guarded for practical reasons.

Fire Safety To avoid a fire or explosion, follow these instructions.

� Do not smoke, weld, grind, or use open flames where flammablematerials are being used or stored.

� Provide adequate ventilation to prevent dangerous concentrations ofvolatile materials or vapors. Refer to local codes or your material MSDSfor guidance.

� Do not disconnect live electrical circuits while working with flammablematerials. Shut off power at a disconnect switch first to preventsparking.

� Know where emergency stop buttons, shutoff valves, and fireextinguishers are located. If a fire starts in a spray booth, immediatelyshut off the spray system and exhaust fans.

� Clean, maintain, test, and repair equipment according to the instructionsin your equipment documentation.

� Use only replacement parts that are designed for use with originalequipment. Contact your Nordson representative for parts informationand advice.

Safety 1-3


Grounding WARNING: Operating faulty electrostatic equipment is hazardous and cancause electrocution, fire, or explosion. Make resistance checks part of yourperiodic maintenance program. If you receive even a slight electrical shockor notice static sparking or arcing, shut down all electrical or electrostaticequipment immediately. Do not restart the equipment until the problem hasbeen identified and corrected.

Grounding inside and around the booth openings must comply with NFPArequirements for Class 2, Division 1 or 2 Hazardous Locations. Refer toNFPA 33, NFPA 70 (NEC articles 500, 502, and 516), and NFPA 77, latestconditions.

� All electrically conductive objects in the spray areas shall be electricallyconnected to ground with a resistance of not more than 1 megohm asmeasured with an instrument that applies at least 500 volts to the circuitbeing evaluated.

� Equipment to be grounded includes, but is not limited to, the floor of thespray area, operator platforms, hoppers, photoeye supports, andblow-off nozzles. Personnel working in the spray area must begrounded.

� There is a possible ignition potential from the charged human body.Personnel standing on a painted surface, such as an operator platform,or wearing non-conductive shoes, are not grounded. Personnel mustwear shoes with conductive soles or use a ground strap to maintain aconnection to ground when working with or around electrostaticequipment.

� Operators must maintain skin-to-handle contact between their hand andthe gun handle to prevent shocks while operating manual electrostaticspray guns. If gloves must be worn, cut away the palm or fingers, wearelectrically conductive gloves, or wear a grounding strap connected tothe gun handle or other true earth ground.

� Shut off electrostatic power supplies and ground gun electrodes beforemaking adjustments or cleaning powder spray guns.

� Connect all disconnected equipment, ground cables, and wires afterservicing equipment.

Action in the Event of a Malfunction If a system or any equipment in a system malfunctions, shut off the systemimmediately and perform the following steps:

� Disconnect and lock out electrical power. Close pneumatic shutoffvalves and relieve pressures.

� Identify the reason for the malfunction and correct it before restarting theequipment.

Disposal Dispose of equipment and materials used in operation and servicingaccording to local codes.

Safety1-4


Description 2-1


Section 2Description

IntroductionThe Sure Coat automatic powder spray gun electrostatically charges andsprays organic or metallic powder coatings. It is used with a Sure Coatautomatic gun control unit, or a Sure Coat Modular Gun Control System, oran iControl system.

FeaturesSee Figure 2-1 or 2-2.

The spray gun features a straight-through powder path, which minimizessurfaces for impact fusion to occur. The rigid powder tube and all powderpath components are easy to remove, clean, and inspect.

The negative-polarity, integral power supply (voltage multiplier) isuser-replaceable. All spray guns are equipped with gun air to preventpowder from collecting on the electrode.

The quick-disconnect hose connector (1) allows the operator to quicklyswitch powder feed hoses while performing a color change.

Mounting Configurations The spray gun is available in both bar- and tube-mount configurations.

Refer to Table 2-1 for a description of the variations available for bothmounting configurations.

Description2-2


Mounting Configurations (contd)

Table 2-1 Mounting Configurations

Gun Type Variations Illustration

Tube-mount The tube-mount gun is available in the following lengths:

� 0.91 m (3 ft)

� 1.22 m (4 ft)

� 1.52 m (5 ft)

� 1.83 m (6 ft)

Figure 2-1

Bar-mount The bar-mount gun may accept either of the following size gunbars in any lengths:

� 11/4-in. OD

� 5/8-in. OD

NOTE: The 11/4-in. OD gun bar is a new, larger diameter, rigidbar. Refer to Parts for ordering information for the standard 3-and 4-ft long gun bar mounting assemblies.

Figure 2-2

Theory of OperationSee Figure 2-1 or 2-2.

The control unit supplies low-voltage dc power to the voltage multiplier inthe spray gun body (2). The multiplier converts the low-voltage dc power tothe high electrostatic voltage needed for powder coating. The voltagegenerates a high-strength electrostatic field between an electrode in thenozzle (3) and the grounded part in front of the spray gun. The electrostaticfield produces a corona discharge around the electrode.

Flow rate air pressure pumps the powder from the feed hopper, through thefeed hose, into the hose connector (1), and out through the spray gun’snozzle. As the powder particles are sprayed past the electrode in thenozzle, they pick up an electrostatic charge and are attracted to thegrounded parts.

The spray pattern is controlled by the shape of the nozzle, the flow rate airpressure, and the electrostatic field generated between the electrode andthe grounded part.

Description 2-3


1

2

3

4

Figure 2-1 Tube-Mount Gun

1. Hose connector2. Body

3. Nozzle 4. Mounting tube

1

4

3

2

Figure 2-2 Bar-Mount Gun

1. Hose connector2. Body

3. Nozzle 4. Mounting bar

Description2-4


SpecificationsRefer to the following specifications to operate the spray gun.Specifications are subject to change without notice.

Electrical OutputMaximum rated output voltage at the electrode 95 kV � 10%

Maximum rated output current at the electrode 100 A � 10%

Air Pressure RequirementsMinimum input air: 4 bar (60 psi)

Maximum input air: 7 bar (100 psi)

Purge air: 5.6−6.6 bar (80−95 psi) at 227−255 l/min (8−9 scfm)

Gun air: 0.3 bar (5 psi) 6 l/min (0.2 scfm)

Air Quality RequirementsPowder spray systems require clean, dry, oil-free operating air. Moist oroil-contaminated air can cause the powder to clog in the pump’s venturithroat, powder feed hose, or gun powder path.

Use 3-micron filter/separators with automatic drains and a refrigerated orregenerative desiccant-type air dryer that can produce a 3.4 �C (38 �F) orlower dewpoint at 7 bar (100 psi).

Equipment RatingThis equipment is rated for use in an explosive environment (Class II, Division I).

Special Conditions for Safe Use � The Sure Coat Applicator must be used with one of the following

controllers: iControl, Vantage, or Sure Coat Automatic Rack Controller.

� The equipment is intended to be used in the ambient temperature from 0 �C to 40 �C.

Description 2-5


Dimensions

1673.35 mm (65.88 in.)1368.55 mm (53.88 in.)

77.0 mm(3.03 in.)

43.4 mm(1.71 in.)

1063.75 mm (41.88 in.)

1978.15 mm (77.88 in.)

Figure 2-3 Tube-Mount Gun Dimensions

440.4 mm(17.34 in.)

334.0 mm(13.15 in.)

77.0 mm(3.03 in.)

131.8 mm(5.19 in.)

42.4 mm(1.67 in.)

43.4 mm(1.71 in.)

Figure 2-4 Bar-Mount Gun Dimensions

Description2-6


Installation 3-1


Section 3Installation

WARNING: Allow only qualified personnel to perform the following tasks.Follow the safety instructions in this document and all other relateddocumentation.

MountingUse one of the following procedures to mount the spray gun on a fixed gunstand or on an oscillating or reciprocating gun mover. Use the mountingassemblies listed in Parts to mount the spray gun.

Tube-Mount Gun MountingSee Figure 3-1.

Types of Tube-Mounting AssembliesThree types of tube-mounting assemblies are available:

Mounting Type Application

Standard gun barassembly

Mounts to a standard 25.4-mm (1.0-in.) roundgun bar.

The spray gun is fixed on the horizontal plane.

Pivoting gun barassembly

Mounts to a standard 25.4-mm (1.0-in.) roundgun bar.

Allows spray gun to pivot vertically while themounting assembly is stationary.

Extrusion gun mountassembly

Mounts to a standard 20 x 20-mm square,T-slotted aluminum extrusion.

Typically used on vertical oscillators with offsetgun bar assemblies.

Spray gun is fixed on the horizontal plane.

Installation3-2


Installing Tube-Mounting AssembliesSee Figure 3-1. Use the appropriate procedure to mount the spray gunusing one of the tube-mounting assemblies.

Table 3-1 Installing Tube-Mounting Assemblies

Standard Gun Bar Assembly Pivoting Gun Bar Assembly Extrusion Gun Mount Assembly

1. Place the mounting body (2)on to a 25.4-mm (1-in.)diameter bar (1). Tightenhandle A.

2. Slide the gun cable, airtubing, and mounting tube (6)through the mountingsleeve (5). Tighten theclamping screw (4) using a6-mm hex wrench.

3. Insert the gun cable and airtubing into the hose supportbracket (3) and slide thebracket onto the gunmounting tube.

1. Place the mounting body (2)on to a 25.4-mm (1-in.)diameter bar (1). Tightenhandles A and B.

2. Slide the gun cable, airtubing, and mounting tube (6)through the mountingsleeve (5). Tighten theclamping screw (4) using a6-mm hex wrench.


1. Secure the support plate (8)to the mounting sleeve (5)using the 3/8-16 x 1-in. longscrews (9).

2. Install the T-slot nuts (10) intothe slot of the square,aluminum gun barassembly (11).

3. Install the M8 x 30 screws (7)through the support plate andinto the T-slot nuts. Tightenthe screws securely.

4. Slide the gun cable, airtubing, and mounting tube (6)through the mounting sleeve.Tighten the clampingscrew (4) using a 6-mm hexwrench.


Adjusting the Tube-Mounting AssembliesSee Figure 3-1. Adjust the tube-mounting assembly using these guidelines.

Table 3-2 Adjusting the Tube-Mounting Assemblies

Item Description Position Adjustment

4 Clamping screw Allows horizontal adjustment of the spray gun by either slidingthe mounting tube freely or locking it into the mounting sleeve.

7 M8 x 30 Screws Adjust the vertical position of the entire spray gun assembly.

A Handle Adjusts the vertical position of the entire spray gun and tubemounting assembly.

B Handle Pivots the spray gun while the tube mounting assembly staysstationary.

Installation 3-3


4

1

2

5

6

A3

4

1

2

5

6

A3

4

8

5

6

3

7

9

10

11

B

Standard Gun Bar Assembly

Pivoting Gun Bar Assembly

Extrusion Gun Mount Assembly

Figure 3-1 Installing Tube-Mounting Assemblies

1. 25.4-mm (1-in.) dia bar2. Mounting body3. Hose support bracket4. Clamping screw

5. Mounting sleeve6. Mounting tube7. M8 x 30 Screws8. Support plate

9. 3/8-16 x 1-in. long screws10. T-slot nuts11. Square, aluminum gun bar

assembly

Installation3-4


Bar-Mount Gun Mounting See Figure 3-2. The bar-mount gun mounting clamp can accept either11/4-in. (2) or 5/8-in. OD (3) gun bars. Insert a 2.5-mm hex-shaped wrenchthrough the set screw hole (1) to tighten the mounting clamp to a 5/8-in. ODgun bar.

3

1

2

Figure 3-2 Gun Mounting Clamp

1. Set screw hole2. 11/4-in. OD gun bar opening

3. 5/8-in. OD gun bar opening

See Figure 3-3.

1. Secure the mounting body (6) on a 25.4-mm (1-in.) diameter bar (7).Tighten handle A.

NOTE: The gun mounting bar (3) has a protective orange cap (5) on oneend. The end with the protective orange cap must be outside of the booth.

2. Slide the open end of the gun mounting bar through the lockingbody (4). Tighten handle B.

3. Loosen the set screw in the mounting clamp (2).

4. Insert the open end of the gun bar into the mounting clamp and tightenthe set screw.

5. Adjust the gun bar assembly using the following guidelines:

Item Description Position Adjustment

1 Pivot screw Pivots the spray gun, but not thegun bar.

A Handle Adjusts the spray gun’s verticalposition.

B Handle Adjusts the spray gun’shorizontal position.

NOTE: The hose support bracket and hook and loop tape strap areincluded in the powder feed hose support bracket kit. Refer to the Partssection for ordering information.

6. Use the hook and loop tape strap (8) to secure the hose supportbracket (9) to the end of the gun mounting bar.

Installation 3-5


7

6

5

4

B

A

89

3

21

Figure 3-3 Bar-Mount Gun Mounting

1. Pivot screw2. Mounting clamp3. Gun mounting bar

4. Locking body5. Orange cap6. Mounting body

7. 25.4-mm (1-in.) diameter bar8. Hook and loop tape strap9. Hose support bracket

Connections

WARNING: All electrically conductive equipment in the spray area must begrounded. Ungrounded or poorly grounded equipment can store anelectrostatic charge which can give personnel a severe shock or arc andcause a fire or explosion.

The tube-mount gun is shipped with gun cable and air tubing extensionsconnected to the back of the spray gun. This allows the cable and air tubingconnections to be made without having to disassemble the spray gun.

Powder Feed Hose InstallationTwo barbed hose connector fittings are shipped with the spray gun: an11-mm fitting (attached to the spray gun) and a 1/2-in. fitting (shipped loose).Select the correct fitting based on the size of feed hose in your system.

NOTE: To increase powder flow and keep an even distribution of air in thepowder, keep the powder feed hose as short as possible. The powder feedhose should be no longer than 16 m (50 ft) long.

CAUTION: Do not overtighten any threaded parts. Overtighteningthreaded parts may result in stripped threads or cracked parts.

Installation3-6


1. See Figure 3-4. Unscrew the hose connector nut (3) and remove thenut and barbed hose connector (4) from the hose connector body (5).Leave the nut installed on the barbed hose connector.

2. Slide the supplied hose clamp (2) onto the powder feed hose (1).

NOTE: Do not install the powder feed hose all the way against the nut.The nut should be able to move back and forth on the barbed hoseconnector.

3. Install the powder feed hose over the appropriate-sized barbed hoseconnector. Secure the feed hose with the hose clamp installed in step 2.

4. Push the barbed hose connector into the hose connector body until itbottoms out. Tighten the nut no more than 1/8 turn past finger tight tosecure the barbed hose connector to the hose connector body.

5. Connect the other end of the powder feed hose to the powder pump.

6. Tube-Mount Guns Only: If using the spray gun in a quick color changesystem, follow these steps to install a second feed hose:

a. Order another hose connector kit that is the same size that youinstalled.

b. Install the second feed hose onto another barbed hose connectorfitting/nut assembly following steps 2−5.

c. Push the second feed hose assembly onto one of the fittings on thehose support bracket.

2 3 4 51

Figure 3-4 Powder Feed Hose Installation

1. Powder feed hose2. Hose clamp3. Nut

4. Barbed hose connector5. Hose connector body

Installation 3-7


Gun Cable and Air Tubing Installation1. See Figure 3-5. Connect an appropriate length of clear 4-mm gun air

tubing from the gun air connector (5) on the spray gun to the gun airconnector (3) on the control unit.

2. Connect the eight-pin end of the gun cable to the appropriate gunreceptacle (7) on the control unit.

3. Connect the three-pin end of the gun cable to the gun using one of thefollowing procedures:

Tube-Mount Guns Bar-Mount Guns

a. Slide back the brass lock nutson the gun cable (8) and thegun extension cable (6).

b. Line up the pins with thesockets and plug the gun cableinto the gun extension cable.

c. Screw the two brass lock nutstogether. Securely tighten thelock nuts.

NOTE: It is recommended toinstall a connector cover (10) overthe brass cable connectors afterconnecting them. The covershields the connectors from staticand reduces electrical noise in thecontrol circuit. Refer to theOptions section for the cover partnumber.

a. Slide back the brass lock nuton the gun cable (8).

b. Line up the alignment mark onthe cable connector with thealignment mark on the gun endcap.

c. Plug the gun cable connectorinto the gun receptacle (9).

d. Slide the threaded brass locknut up to the gun, screw it intothe end cap and tighten itsecurely.

4. Secure the powder feed hose(s) (4), air tubing, and gun cable to thehose support bracket using the supplied hook and loop tape strap.

5. Use spiral-cut tubing to secure the gun cable, powder feed hose, and airtubing to the gun mounting bar and/or stand or reciprocator. Make surethat the cable, hose, or tubing cannot be abraded, cut, or run over bymoving equipment.

Installation3-8


1 23

3

9

5

3

56

Bar-Mount Gun

Tube-Mount Gun

2 1

Nordson

AC IN

2 1

2 1 2 1

2 1 2 1

2 1 2 1

234

5678

9101112

1314

15

16

1

234

5678

9101112

131416

12

1

15

15

iControlCabinet

7

10

8

8

Figure 3-5 Gun Cable and Air Tubing Installation

1. Flow rate air connector2. Atomizing air connector3. Powder feed hose4. Gun air connector (control unit)

5. Gun air connector (gun)6. Extension cable7. Control unit receptacle

8. Gun cable9. Bar-mount gun receptacle

10. Connector cover (optional)

Operation 4-1


Section 4Operation


WARNING: This equipment can be dangerous unless it is used inaccordance with the rules laid down in this manual.

IntroductionThis section describes basic operating procedures for the Sure Coatautomatic powder spray gun. Refer to your other powder applicationequipment manuals for instructions for operating other system components.

Startup WARNING: Do not operate the spray gun if the resistance of the multiplieror electrode support assembly are not within the ranges specified inTroubleshooting. Failure to observe this warning may result in personalinjury, fire, and property damage.

NOTE: Refer to Operation in the appropriate control unit manual fordetailed operation instructions.

1. Make sure that the following conditions are met before starting up thespray gun and control unit:

� The booth exhaust fans are on.

� The powder recovery system is operating.

� The powder in the feed hopper is thoroughly fluidized.

� The gun cable, feed hose, and air tubing are correctly connected tothe spray gun, pump, and control unit.

Operation4-2


Startup (contd)

2. Set the kV. Refer to the control unit manual for instructions.

3. Set the flow rate and atomizing air pressures.

NOTE: The air pressures given are average starting points. Pressureswill vary according to required film build, line speed, and partconfiguration. Adjust the pressures to obtain the desired results.

Air Pressure Setting Function

Flow Rate 1.4 bar (20 psi) Controls the volume of thepowder delivered to the spraygun

Atomizing 1.0 bar (15 psi) Controls the velocity anddensity (powder-to-air ratio)of the powder

NOTE: Gun air pressure is controlled by a fixed-orifice restrictor on thecontrol unit’s back panel.

4. Trigger the spray gun. Adjust the flow rate and atomizing air pressuresuntil you obtain the desired spray pattern.

Quick Color ChangeSee Figure 4-1. In a quick color change system, the powder feed centerpurges the spray gun internally during the color change process. Refer toyour quick color change system manual for information about performing acolor change.

Two hose connector/powder feed hose assemblies (4) are used for eachspray gun in a quick color change system: one for light-colored powders,and one for dark-colored powders. The hose hanger bracket (2) hasfittings (5) on either side to hold the assemblies.

NOTE: Optional quick-disconect fittings are available to simplify thisprocedure. Refer to Quick Disconnect Fittings and Components onpage 8-2.

After the purge process has been completed, switch the powder feed hosesusing the following procedure.

1. Loosen the nut (3) from the hose connector body (1).

NOTE: The nut will stay on the hose connector/powder feed hoseassembly.

2. Pull the hose connector/powder feed hose assembly (4) from the hoseconnector body and push it on the empty hose hanger bracket fitting (5)until it fits snugly.

Operation 4-3



3. Pull the other hose connector/powder feed hose assembly from thehose hanger bracket fitting and push it into the hose connector bodyuntil it bottoms out.

4. Tighten the nut no more than 1/8 turn past finger tight.

3

5

1

2

4

Figure 4-1 Quick Color Change

1. Hose connector body2. Hose hanger bracket3. Nut

4. Hose connector/powder feedhose assembly

5. Hose hanger bracket fitting

Shutdown1. Turn the main power switch on the control unit to the off position.

2. Turn off the flow rate and atomizing air pressures at the control unit.

3. Ground the gun electrode to discharge any residual voltage.

4. Perform the Daily Maintenance procedure.

Operation4-4


Maintenance

WARNING: Turn off the electrostatic voltage and ground the gun electrodebefore performing the following tasks. Failure to observe this warning couldresult in a severe shock.

Daily MaintenanceNOTE: Depending on your system’s operation, you may not need toperform this procedure every day. If you regularly perform color changeswith a powder feed center, the spray gun will be purged internally each timea color change is performed. If this is the case, perform this procedureevery 2−3 days.

See Figure 4-2.

1. Shut down and lock out the gun control unit.

2. Disconnect the powder feed hose from the powder pump. Blow thepowder out of the powder feed hose and spray gun with anOSHA-approved, low-pressure air gun. Never blow air through thepowder feed hose from the spray gun into the powder pump.

3. Unscrew the nozzle nut (5).

4. Pull the nozzle (4) off the spray gun with a slight twisting motion.

5. Pull the electrode support (3) straight out of the body (1). The powdertube (2) will come out with the electrode support.

6. Pull the electrode support off the powder tube.

7. Clean all parts with a low-pressure air gun. Wipe the parts with a clean,dry cloth.

8. Carefully remove fused powder from the parts with a wooden or plasticdowel or similar tool. Do not use tools that will scratch the plastic.Powder will build up and impact-fuse on scratches.

NOTE: If necessary, use a cloth dampened with isopropyl or ethyl alcoholto clean the powder path parts. Remove the O-rings before cleaning thegun parts with alcohol. Do not immerse the spray gun in alcohol. Do notuse any other solvents.

9. Inspect the powder path parts for wear. Replace worn parts.


10. Push the powder tube into the electrode support.

NOTE: The contact wire in the electrode support assembly must be facingdown. The electrode support assembly cannot be installed if the contactwire is not facing down.

11. Push the electrode support and powder tube assembly into the spraygun. Push the assembly into the spray gun until it bottoms out, makingsure that the contact wire on the electrode support is facing down.

Operation 4-5


NOTE: When you install the nozzle, there will be a gap between the baseof the nozzle and the front of the spray gun. Rotate the nozzle 90� from itsprevious position to prevent uneven wear and lopsided patterns.

12. Install the nozzle onto the electrode support.

13. Install the nozzle nut over the nozzle and tighten it until the nozzle nutbottoms out on the spray gun body.

CAUTION: The nozzle nut and the hose connector body at the back of thespray gun hold the powder path components together. If both parts are nottightened, gaps may appear between parts, allowing for powder to build upinside the spray gun and cause contamination during color changes.

1

2

3

4

5

Figure 4-2 Daily Maintenance

1. Body2. Powder feed tube

3. Electrode support4. Nozzle

5. Nozzle nut

Weekly MaintenanceCheck the resistance of the multiplier and electrode support with amegohmmeter as described in the Troubleshooting section. Replace themultiplier or electrode support if the resistance readings are not within thespecified ratings.

Operation4-6


Troubleshooting 5-1


Section 5Troubleshooting


This section contains troubleshooting procedures. These procedures coveronly the most common problems that you may encounter. If you cannotsolve the problem with the information given here, contact your localNordson representative for help.

Troubleshooting Charts

Problem Possible Cause Corrective Action

1. Uneven pattern,unsteady orinadequate powderflow

Low atomizing or flow rate airpressure

Increase the atomizing and/or flowrate air pressures.

Blockage in the spray gun, powderfeed hose, or pump

1. Disconnect the powder feed hosefrom the pump.

2. Blow out the feed hose withcompressed air.

3. Disassemble and clean the pumpand spray gun.

4. Replace the feed hose if it isclogged with fused powder.

Nozzle worn, affecting pattern 1. Remove, clean, and inspect thenozzle.

2. Replace the nozzle if necessary.

3. If excessive wear or impact fusionis a problem, reduce the flow rateand atomizing air pressures.

Continued...

Troubleshooting5-2


Troubleshooting Charts (contd)

Problem Possible Cause Corrective Action1. Uneven pattern,

unsteady orinadequate powderflow (contd)

Improper fluidization of powder inhopper

Increase the fluidizing air pressure.

If the problem persists, remove thepowder from the hopper and inspectthe fluidizing plate. Clean or replacethe fluidizing plate if it iscontaminated.

Damp powder 1. Check the powder supply, airfilters, and dryer.

2. Replace the powder supply ifcontaminated.

2. Voids in powderpattern

Worn nozzle Remove and inspect the nozzle.Replace it if it is worn.

Plugged powder path Perform the Daily Maintenanceprocedure in this manual.

3. Loss of wrap, poortransfer efficiency

NOTE: Before checking possiblecauses, check the error code onthe control unit and perform theerror code corrective action in thecontrol unit manual.

Low electrostatic voltage Increase the electrostatic voltage.

Poor electrode connection Perform the Electrode SupportAssembly Continuity Check in thissection.

Poorly grounded parts Check the conveyor chain, rollers,and part hangers for powder buildup.The resistance between the parts andground must be 1 megohm or less.For best results, 500 ohms or less isrecommended.

4. No kV output from thespray gun

NOTE: Before checking possiblecauses, check the error code onthe control unit and perform theerror code corrective action in thecontrol unit manual.

Damaged gun cable(Error codes 7 or 8)

Perform the Gun Cable ContinuityChecks in this section.

If an open or short is found, replacethe cable.

Malfunctioning control unit If you found no problem with the guncable, refer to the Troubleshootingsection of the control unit manual.

Malfunctioning multiplier(Error codes 7 or 8)

Perform the Multiplier AssemblyResistance Checks in this section.

Poor electrode connection Perform the Electrode SupportAssembly Continuity Check and theContact Tip Resistance Check in thissection.

Troubleshooting 5-3


Continuity and Resistance ChecksWARNING: Turn off the electrostatic voltage and ground the gun electrodebefore performing the following tasks. Failure to observe this warning couldresult in a severe shock.

Gun Resistance CheckSee Figure 5-1.

1. Shut down and lock out the powder coating system.

2. Disconnect the gun cable from the spray gun.

3. Remove the nozzle and nozzle nut from the spray gun.

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

5. Connect the megohmmeter (4) probes to the shorting plug ring tongterminal and gun electrode (3). If the reading is infinite, reverse theprobes.

6. Check the megohmmeter reading. Resistance should be between 150 and 220 M at 500 volts.

7. If the reading is not between 150 and 220 M, perform the MultiplierAssembly Resistance Checks and Electrode Support AssemblyResistance Check in this section.

1

4 3

2

Figure 5-1 Gun Resistance Check

1. Shorting plug connector2. Cable connector

3. Electrode 4. Megohmmeter

Note: Tube-mount gun shown without hose support bracket for clarity.

Troubleshooting5-4


Multiplier Assembly Resistance ChecksThe multiplier assembly consists of the voltage multiplier, contact tip, andmultiplier nut. If the resistance check of the multiplier and contact tipassembly does not give the required readings, check the multiplier andcontact tip separately.

Multiplier and Contact Tip Assembly Resistance Check See Figure 5-2.

1. Remove the multiplier assembly from the spray gun. Refer to MultiplierReplacement in the Repair section.

2. Connect the shorting plug connector (1) to the multiplier connector (2).

3. Connect the megohmmeter probes to the shorting plug ring tongterminal and tip of the contact tip (3).

4. Check the megohmmeter reading. Resistance should be between 150 and 220 M at 500 volts.

NOTE: If the reading is infinite, switch the probes.

5. If the reading is not between 150 and 220 M, check the resistance ofthe multiplier and contact tip separately.

12

3

Figure 5-2 Multiplier and Contact Tip Assembly Resistance Check

1. Shorting plug connector2. Multiplier connector

3. Contact tip

Troubleshooting 5-5


Multiplier Resistance Check See Figure 5-3.

1. Unscrew the multiplier nut and pull the contact tip out of the multiplier.

2. Connect the shorting plug connector (1) to the multiplier connector (2).

3. Connect the megohmmeter probes to the shorting plug ring tongterminal and the brass contact (3) inside the front of the multiplier.

4. Check the megohmmeter reading. Resistance should be between 140and 200 M at 500 volts.

NOTE: If the reading is infinite, switch the probes.

5. If the reading is not between 140 and 200 M at 500 volts, replace themultiplier.

Contact Tip Resistance Check 1. See Figure 5-3. Connect the megohmmeter probes to the brass

contacts on the ends of the contact tip.

2. Check the megohmmeter reading. Resistance should be between 15and 24 M at 500 volts.

3. If the reading is not between 15 and 24 M at 500 volts, replace thecontact tip.

12

3

4

Figure 5-3 Multiplier and Contact Tip Resistance Checks

1. Shorting plug connector2. Multiplier connector

3. Brass contact4. Contact tip

Troubleshooting5-6


Electrode Support Assembly Continuity CheckThe electrode support assembly consists of the electrode, electrode holder,electrode support, contact wire, and O-rings. Use the following procedureto check the continuity of the entire electrode support assembly.

1. See Figure 5-4. Remove the electrode support assembly from the spraygun. Refer to Disassembling the Powder Path in the Repair section.

2. Connect a standard ohmmeter’s probes to the contact wire (1) and tip ofthe electrode (2).

3. If there is not continuity, unscrew the electrode holder and check forburn through or arc tracks around the contact wire. Check the electrodespring to make sure it is not broken or bent. Replace any damagedparts.

2

1

Figure 5-4 Electrode Support Assembly Continuity Check

1. Contact wire 2. Electrode

Troubleshooting 5-7


Gun Cable Continuity ChecksUse the following guidelines to check the continuity of the gun cable. Makethe continuity checks with a standard ohmmeter.

Cable Pin FunctionsRefer to Tables 5-1 and 5-2 and Figure 5-5 for descriptions of the pinfunctions.

Table 5-1 Pin Functions—Control Unit End (J1)

Pin Function

1 Blank (no pin)

2 Common

3 + Vdc

4 A feedback

5 Blank (no pin)

6 Ground (gun and cable shield)

7 Gun ID

8 Gun ID

Table 5-2 Pin Functions—Gun End (J2)

Pin Function

1 + Vdc

2 A feedback

3 Common

POWER UNIT END GUN END1

2

3

456

7

8

12

3

J1−1J1−2

J1−3J1−4J1−5

J1−6

J1−7

J1−8

J2−3J2−1

J2−2

CONNECTED TO EYELETMOLDED INTO CONNECTOR

BLANK (NO PIN)

COMMON

+VDCFDBK

IC/TRIBO (NO PIN)

GND

SPIRAL WRAPPED SHIELD

(GUN ID)

(GUN ID)

�A

200�

COMMON

+VDCFDBK�A

CHASSISGND

Figure 5-5 Gun Cable Pins

Troubleshooting5-8


Across the Cable Continuity ChecksRefer to Table 5-3 and Figure 5-5 for a list of continuity checks to performacross the cable.

Table 5-3 Across the Cable Continuity Checks

J1 Pin(Control Unit End)

J2 Pin(Gun End)

2 3

3 1

4 2

Control Unit End Resistance and Continuity ChecksSee Figure 5-5. Perform the following resistance and continuity checks atthe control unit end (J1) of the cable.

� 198−202 between pins 7 and 8

� must be continuity between pin 6 and the metal end of the connector

Repair 6-1


Section 6Repair


WARNING: Turn off the electrostaic voltage and ground the gun electrodebefore performing the following tasks. Failure to observe this warning couldresult in a severe shock.

WARNING: System pressurized. Relieve system pressure beforeservicing. Failure to observe this warning may result in personal injury.

Powder Path RepairNOTE: It is not necessary to remove the spray gun from its mountingassembly in order to perform the powder path repair procedures.

Disassembling the Powder PathSee Figure 6-1.

1. Remove the nozzle nut (7) and nozzle (6) from the spray gun (3).

2. Pull the electrode support (5) straight out of the spray gun; the powdertube (4) will come out with the electrode support.

3. Pull the electrode support off the powder tube.

4. Unscrew the hose connector nut and pull the hose connector/feed hoseassembly off the hose connector body (1).

5. Unscrew the hose connector body from the spray gun.

Repair6-2


Inspecting and Cleaning the Powder Path1. Clean all parts with a low-pressure air gun. Wipe the parts with a clean,

dry cloth.

2. Carefully remove fused powder from the parts with a wooden or plasticdowel or similar tool. Do not use tools that will scratch the plastic.Powder will build up and impact-fuse on scratches.

NOTE: If necessary, use a cloth dampened with isopropyl or ethyl alcoholto clean the powder path parts. Remove the O-rings before cleaning thegun parts with alcohol. Do not immerse the spray gun in alcohol. Do notuse any other solvents.

Assembling the Powder Path


See Figure 6-1.

1. Push the powder tube (4) into the electrode support (5).

NOTE: The contact wire in the electrode support assembly must be facingdown. The electrode support assembly cannot be installed if the contactwire is not facing down.

2. Install the electrode support and powder tube assembly into the spraygun (3). Push the assembly into the spray gun until it bottoms out,making sure that the contact wire is facing down.

NOTE: When you install the nozzle, there will be a gap between the baseof the nozzle and the front of the spray gun. Rotate the nozzle 90� from itsprevious position to prevent uneven wear and lopsided patterns.

3. Install the nozzle (6) onto the electrode support.

4. Install the nozzle nut (7) over the nozzle and tighten the nozzle nut untilit bottoms out against the spray gun.

5. Install the hose connector body (1) onto the back of the spray gun.Tighten the hose connector body no more than 1/8 turn past finger tight.There will be a gap present between hose connector body and the locknut (2).

NOTE: The lock nut is only present on tube-mount guns.

CAUTION: The nozzle nut and hose connector body hold the powder pathcomponents together. If both parts are not tightened, gaps may appearbetween parts, allowing for powder to build up inside the spray gun andcause contamination during color changes.

6. Install the hose connector/feed hose assembly and secure it with thelock nut. Tighten the hose connector/feed hose assembly lock nut nomore than 1/8 turn past finger tight. There will be a gap present betweenthe lock nut and the hose connector body.

Repair 6-3


1

4

5

6

3

7

2

Figure 6-1 Powder Path Repair

1. Hose connector body2. Lock nut3. Spray gun

4. Powder tube5. Electrode support assembly

6. Nozzle7. Nozzle nut

Note: Tube-mount gun shown. Powder path repair procedures are the same for both tube- and bar-mount guns.

Repair6-4


Removal from the Gun MountNOTE: Refer to Mounting in the Installation section for instructions forinstalling the spray gun and mounting assembly after repairs.

Tube-Mount Gun RemovalSee Figure 6-2.

1. Unscrew the hose connector nut (6) and pull the hose connector/powderfeed hose assembly (5) from the hose connector body (4).

2. Disconnect the gun cable from the gun cable extension (8).

3. Disconnect the gun air tubing from the gun air coupling (7).

4. Remove the spray gun from the mount using one of these procedures:

Standard or PivotingGun Bar Assembly

Extrusion Gun MountAssembly

a. Loosen the handle (2).

b. Remove the entire spray gunand mounting clamp (3)assembly.

a. Remove the hose supportbracket.

b. Loosen the clamping screw.

c. Slide the spray gun out of themounting sleeve.

43

2

1

56

8

7

Figure 6-2 Tube-Mount Gun Removal

1. Spray gun2. Handle3. Mounting clamp

4. Hose connector body5. Hose connector/powder feed hose6. Hose connector nut

7. Gun air coupling8. Gun cable extension

Repair 6-5


Bar-Mount Gun RemovalSee Figure 6-3.

1. Unscrew the hose connector nut and pull the hose connector (1) (withpowder feed hose attached) off the hose connector body.

2. Disconnect the clear, 4-mm gun air tubing from its connector (3).

3. Unscrew the brass nut and pull the gun cable’s (2) black connector fromthe multiplier receptacle.

4. Support the spray gun with one hand. Use a 6-mm hex wrench toloosen the pivot screw (5) in the mounting clamp (4).

5. Remove the spray gun from the mounting clamp. Take the spray gun toa clean work area to perform any repair procedures.

6. Refer to Mounting and Connections in the Installation section forprocedures to return the spray gun to its mount.

12

4

3

5

Figure 6-3 Bar-Mount Gun Removal

1. Hose connector2. Gun cable3. Gun air connector

4. Gun mounting clamp5. Pivot screw

Repair6-6


Multiplier Replacement

Tube-Mount Gun Multiplier Replacement

Removing the Multiplier from the Tube-Mount GunSee Figure 6-4.

1. Remove the spray gun from its mount. Refer to Removal from the GunMount in this section for instructions.

2. Disassemble the mounting tube assembly using the following steps:

a. Unscrew the hose connector body/powder tube assembly (1) andremove it from the back of the spray gun.

b. Unscrew the lock nut (2) from the tie-bar tube (5). Remove the tiebar-tube locator (3).

c. Carefully separate the body (14) from the mounting tube (4).

d. Unscrew the cable extension (7) and disconnect the air tubingextension (6) from the mounting bracket (10).

e. Unscrew the tie-bar tube and remove it from the mounting bracket.

3. Remove the screws (8) and O-rings (9) securing the mounting bracket tothe spray gun. Pull the mounting bracket out of the gun body.

4. Hold one hand over the back of the spray gun. Tilt the front end of thespray gun up, allowing the multiplier (11) to fall out.

5. Unscrew the multiplier nut (13) and pull the contact tip (12) out of themultiplier.

Installing the Multiplier in the Tube-Mount Gun


See Figure 6-4.

1. Install the contact tip (12) into the new multiplier (11).

2. Slide the multiplier nut (13) over the contact tip and thread it onto theend of the multiplier until the nut is against the front of the multiplier.

3. Insert the new multiplier into the body (14). Make sure that the multiplieris oriented as shown in Figure 6-4.

4. Install the mounting bracket (10) into the body. Secure the mountingbracket using the screws (8) and O-rings (9).

5. Thread the tie-bar tube (5) into the mounting bracket.

6. Connect the cable extension (7) and air tubing extension (6) into themounting bracket.

Repair 6-7


7. Slide the tie-bar tube and cable and air tubing extensions into the largeend of the mounting tube (4). Push the mounting tube as far as it will goagainst the mounting bracket.

8. Install the tie-bar tube locator (3) over the end of the tie-bar tube andinto the end of the mounting tube.

9. Secure the tie-bar tube locator with the lock nut (2) no more than 1/8 turnpast finger tight.

10. Install the hose connector body/powder tube assembly (1) and tightenthe hose connector body no more than 1/8 turn past finger tight.

11. Install the spray gun on its mount. Refer to Mounting and Connectionsin the Installation section for procedures to return the spray gun to itsmount.

1

9

7

10

4

14

6

5

32

8 11

12

13

Figure 6-4 Tube-Mount Gun Multiplier Replacement

1. Hose connector body/powder tubeassembly

2. Lock nut3. Tie-bar tube locator4. Mounting tube5. Tie-bar tube

6. Air tubing extension7. Cable extension8. Screws9. O-rings

10. Mounting bracket

11. Multiplier12. Contact tip13. Multiplier nut14. Body

Repair6-8


Bar-Mount Gun Multiplier Replacement

Removing the Multiplier from the Bar-Mount GunSee Figure 6-5.

1. Remove all powder path parts from the spray gun. Refer to PowderPath Repair in this section for instructions.

2. Remove the spray gun from its mount. Refer to Bar-Mount GunRemoval in this section for instructions.

3. Remove the screw (1) securing the end cap (2) to the mountingbracket (5). Remove the end cap.

4. Remove the screws (3) and O-rings (4) from the mounting bracket. Pullthe mounting bracket out of the body (9).

5. Hold one hand over the back of the body. Tilt the front end of the spraygun up, allowing the multiplier (6) to fall out of the body.

6. Unscrew the multiplier nut (8) and pull the contact tip (7) out of themultiplier.

Installing the Multiplier in the Bar-Mount Gun


See Figure 6-5.

1. Install the contact tip (7) into the new multiplier (6).

2. Slide the multiplier nut (8) over the contact tip and thread it onto the endof the multiplier until the nut is against the front of the multiplier.

3. Insert the new multiplier into the body (9). Make sure that the multiplieris oriented as shown in Figure 6-5.

4. Secure the mounting bracket (5) to the body using the screws (3) andO-rings (4).

5. Secure the end cap (2) to the mounting bracket using the screw (1).

6. Install the powder path parts.

7. Install the spray gun on its mount. Refer to Mounting and Connectionsin the Installation section for procedures to return the spray gun to itsmount.

Repair 6-9


23

1

4

5

6

7

8

9

Figure 6-5 Bar-Mount Gun Multiplier Replacement

1. Screw2. End cap3. Screws

4. O-rings5. Mounting bracket6. Multiplier

7. Contact tip8. Multiplier nut9. Body

Repair6-10


Parts 7-1


Section 7Parts

Introduction To order parts, call the Nordson Finishing Customer Support Center at (800)433-9319 or your local Nordson representative. Use the parts lists in thissection to locate and order parts.

Using the Illustrated Parts List Numbers in the Item column correspond to numbers that identify parts inillustrations following each parts list. The code NS (not shown) indicatesthat a listed part is not illustrated. A dash (—) is used when the part numberapplies to all parts in the illustration.

The number in the Part column is the Nordson Corporation part number. Aseries of dashes in this column (- - - - - -) means the part cannot be orderedseparately.

The Description column gives the part name, as well as its dimensions andother characteristics when appropriate. Indentions show the relationshipsbetween assemblies, subassemblies, and parts.

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

� 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 quantity required per unit,assembly, or subassembly. The code AR (As Required) is used if the partnumber is a bulk item ordered in quantities or if the quantity per assemblydepends on the product version or model.

Letters in the Note column refer to notes at the end of each parts list. Notescontain important information about usage and ordering. Special attentionshould be given to notes.

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

Parts7-2


Spray Gun Parts

Spray Gun AssembliesThe spray gun part number and serial number are printed onto the label onthe bottom of the body. To order the correct parts for your spray gun, matchthe part number on the label with the description listed in the following chart.

Part Description NoteObsolete 3-ft TUBE-MOUNT GUN, Sure Coat automatic, negative

Obsolete 4-ft TUBE-MOUNT GUN, Sure Coat automatic,negative

Obsolete 5-ft TUBE-MOUNT GUN, Sure Coat automatic,negative

Obsolete 6 ft TUBE MOUNT GUN, Sure Coat automatic, negative

Obsolete BAR-MOUNT GUN, Sure Coat automatic, negative

Refer to Service Kits on page 7-12 for cables and hose connectors requiredfor installation and operation.

Parts 7-3


Tube-Mount Gun Parts See Figure 7-1.

Item Part Description Quantity Note1 1005028 NUT, lock, nozzle 1 I

2 1010661 NOZZLE, flat spray, 13-mm ID, 4 mm 1 C, I

2 1010662 NOZZLE, flat spray, 13-mm ID, 2.5 mm 1 C, I

3 1010561 HOLDER, electrode, M4 1 I

4 1010562 ELECTRODE, spring contact, 0.094-in. diameter 1 I

5 1093572 KIT, support, electrode, heavy duty 1 I

6 940163 � O-RING, silicone, 0.625 x 0.75 x 0.063 in. 2


8 - - - - - - � CONTACT, wire, electrode 1

9 - - - - - - � SUPPORT, electrode, gun 1

10 341738 HOUSING, gun, with label, Sure Coat automatic 1 A

11 327706 NUT, Sure Coat multiplier, outlet 1

12 1006352 CONTACT, multiplier, packaged 1

13 288552 MULTIPLIER, 95 kV, negative 1

14 327986 O-RING, silicone, 2.063 x 2.25 x 0.094 in. 1

15 327979 GASKET, multiplier 1

16 - - - - - - BRACKET, sealing 1

17 972398 CONNECTOR, round, male, M4 tubing x M5thread

1

18 940060 O-RING, Viton, 0.125 x 0.25 x 0.063 in. 2

19 327981 SCREW, cheese head, recessed, M4 x 25, blackzinc

2

20 1006319 TUBE, tie-bar, 3 ft, packaged 1 B








NOTE A: The spray gun identification label on this part must be recreated when you replace this part. Whenordering this part, call Nordson customer service and give the representative the part number and serialnumber for your spray gun.

B: Check the spray gun part number on the identification label and note the gun length given in Spray GunAssemblies before ordering these parts.

C: Standard nozzles shipped with new spray guns. For optional nozzles refer to the Options section.

I: Part is not included in kit 1607023.

Continued...

Parts7-4


Tube-Mount Gun Parts (contd)

Item Part Description Quantity Note22 1009705 TUBE, powder, 0.50-in. ID, 3 ft 1 B

22 1009704 TUBE, powder, 0.50-in. ID, 4 ft 1 B



23 940156 O-RING, silicone, 0.563 x 0.688 x 0.063 in. 4 D

24 1020466 O-RING, PUR, 0.625 x 0.75 x 0.063 in., 70 duro 1

25 1010723 BODY, connector, hose 1

26 1010724 CONNECTOR, hose, barb, 11 mm 1 D

26 1010726 CONNECTOR, hose, barb, 1/2 in. 1 D

27 1010725 NUT, connector, hose 1 D

28 1006316 TUBE, mount, 3 ft 1 B

28 1006317 TUBE, mount, 4 ft 1 B

28 1006318 TUBE, mount, 5 ft 1 B

28 1032271 TUBE, mount, 6 ft 1 B

29 1001798 LOCATOR, tensioning, tube 1

30 327719 NUT, tension, tube mount 1

31 1003572 HANGER, hose, automatic gun 1

31A 1601795 � HANGER, hose barb, automatic gun 2 H

32 340637 O-RING, PUR, 0.562 x 0.687 x 0.062 in. 2

NS 247006 CLAMP, hose, 0.673−0.795-in. OD 1 E

NS 939247 CLAMP, hose, snap-it 2 F

NS 1001222 CABLE, extension, Sure Coat automatic gun 1

NS 900617 TUBE, polyurethane, 4-mm OD, clear AR

NS 1003964 UNION, straight, 4 mm, plastic 1

NS 301841 STRAP, hook and loop tape, with buckle, 25 x3 cm

1

NS 1030482 PARTS POSTER, Sure Coat automatic gun 1 GNS 1038539 NOZZLE, flat spray, 13−mm ID, 3−mm 1 I

NOTE B: Check the spray gun part number on the identification label and note the position length given in SprayGun Assemblies before ordering these parts.

D: These parts are available in the hose connector kits. Refer to Hose Connector Kits.

E: Use this hose clamp with 11-mm powder feed hoses.

F: Use this hose clamp with 1/2-in. powder feed hoses.

G: This is a laminated, 11 x 17-inch full-color photograph of the gun. This exploded view of the gun showsthe part numbers next to the individual gun parts. The optional parts poster is not included with the gun.

H: Part number 1601795 comes with 2 sets of hose barbs and screws.

I: Part is not included in kit 1607023.

AR: As Required

NS: Not Shown

Parts 7-5


10

5

4

9

83

2

1

17

1615

14

25

31

24

29

28

20

21

7

1918

22

6

32

23

27

26

30

13

12

11

31A

Figure 7-1 Tube-Mount Gun Parts

Parts7-6


Bar-Mount Gun Parts See Figure 7-2.

Item Part Description Quantity Note1 1005028 NUT, lock, nozzle 1 F

2 1010661 NOZZLE, flat spray, 13-mm ID, 4 mm 1 E, F

2 1010662 NOZZLE, flat spray, 13-mm ID, 2.5 mm 1 E, F

3 1010561 HOLDER, electrode, M4 1 F

4 1010562 ELECTRODE, spring contact, 0.94-in. diameter 1 F

5 1093572 KIT, support, electrode, heavy duty 1 F



8 - - - - - - � CONTACT, wire, electrode 1

9 - - - - - - � SUPPORT, electrode, 13-mm ID 1

10 341738 HOUSING, gun, with label, Sure Coat automatic 1 A

11 327706 NUT, Sure Coat, multiplier, outlet 1

12 1006352 CONTACT, multiplier, packaged 1

13 288552 MULTIPLIER, 95 kV, negative polarity 1


15 327979 GASKET, multiplier 1

16 - - - - - - BRACKET, mount, ball 1

17 940060 O-RING, Viton, 0.125 x 0.25 x 0.063 in. 2

18 327981 SCREW, cheese head, recessed, M4 x 25 2

19 327980 SCREW, pan, recessed, M5 x 12, black zinc 1

20 327969 CAP, end, automatic gun 1

21 972398 CONNECTOR, round, male, M4 tubing x M5 1

22 327721 CLAMP, fixed 1

23 982067 SCREW, set, cup, M5 x 5, black 3

24 327730 CLAMP, pivot 1

25 982501 SCREW, socket, M8 x 40, black 1

26 1009706 TUBE, powder feed, 0.50-in. ID, bar mount 1

27 940156 O-RING, silicone, 0.563 x 0.688 x 0.063 in. 4 B

28 1020466 O-RING, PUR, 0.625 x 0.75 x 0.063 in., 70 duro 1

29 1016047 BODY, connector, hose, bar mount 1


31 1010724 CONNECTOR, hose, barb, 11 mm 1 B

31 1010726 CONNECTOR, hose, barb, 1/2 in. 1 B

32 1010725 NUT, connector, hose 1 B

33 340637 O-RING, PUR, 0.562 x 0.687 x 0.062 in. 2

NS 247006 CLAMP, hose, 0.673−0.795-in. OD 1 C

NS 939247 CLAMP, hose, snap-it 1 DNS 1038359 NOZZLE, flat spray, 13−mm ID, 3−mm 1 F

Parts 7-7


NoteQuantityDescriptionPartItemNOTE A: The gun identification label on this part must be recreated when you replace this part. When ordering this

part, call Nordson customer service and give the representative the part number and serial number foryour spray gun.

B: These parts are available in the hose connector kits. Refer to Hose Connector Kits.

C: Use this hose clamp with 11-mm powder feed hoses.

D: Use this hose clamp with 1/2-in. powder feed hoses.

E: Standard nozzles shipped with new spray guns. For optional nozzles refer to the Options section.

F: Part is not included in kit 1607024.

10

5

4

7

98

63

2

119

20

23

21

13

30

26

23

25

24

22

1817

16

15

14

12

11

29

28

33

2731

32

Figure 7-2 Bar-Mount Gun Parts

Parts7-8


Gun Body Service KitsPart Description Note

1607023 KIT, repair, gun body, 5 ft A1607024 KIT, repair, gun body, bar B

NOTE A: See Tube-Mount Gun Parts on page 7-3.

B: See Bar-Mount Gun Parts on page 7-6.

Mounting Assemblies

Tube-Mount Gun Mounting Assemblies

Standard Gun Bar Assembly for Tube-Mount GunsSee Figure 7-3. Use this assembly to mount a tube-mount gun to aconventional fixed gun stand or oscillator equipped with gun bars.

Item Part Description Quantity Note— 1010717 MOUNTING ASSEMBLY, Sure Coat automatic gun 1

1 248957 � HANDLE, adjustment, 3/8-16 x 1.77 in. 1

2 - - - - - - � MOUNT, clamp, automatic gun 1

3 - - - - - - � MOUNT, sleeve, automatic gun 1

4 981561 � SCREW, socket, 3/8-16 x 1.00 in., zinc 3

1

2

3

4

Figure 7-3 Standard Gun Bar Assembly for Tube-Mount Guns

Parts 7-9


Pivoting Gun Bar Assembly for Tube-Mount GunsUse this assembly to mount a tube-mount gun to a conventional fixed gunstand or oscillator equipped with gun bars.

See Figure 7-4.

Item Part Description Quantity Note— 341756 MOUNT, tube holder, assembly 1


2 983061 � WASHER, flat, 0.406 x 0.812 x 0.065 in., zinc 1


4 - - - - - - � MOUNT, clamp, automatic gun 1

5 - - - - - - � MOUNT, sleeve, automatic gun 1

6 981561 � SCREW, socket, 3/8-16 x 1.00 in., zinc 3

1

4

5

6

2

3

Figure 7-4 Pivoting Gun Bar Assembly for Tube-Mount Guns

Parts7-10


Extrusion Gun Mount Assembly for Tube-Mount GunsSee Figure 7-5. Use this assembly to mount a tube-mount gun to a rigidoscillator bracket on a quick color change booth.

Item Part Description Quantity Note— 1016515 PLATE, adapter, support, gun bar assembly 1

— 1013964 � MOUNT, sleeve, with screws, Sure Coatautomatic

1

1 - - - - - - � � MOUNT, sleeve, automatic gun 1

2 981561 � � SCREW, socket, 3/8-16 x 1.00 in., zinc 3

3 981528 � SCREW, socket, M8 x 30, zinc 2

4 1016458 � PLATE, attachment, support, gun bar 1

5 1016533 � NUT, T-slot, steel, M8 2

2

1

3

4

3

25

Figure 7-5 Extrusion Gun Mount Assembly for Tube-Mount Guns

Parts 7-11


Bar-Mount Gun Mounting Assemblies

3-ft Gun Bar AssemblySee Figure 7-6.

Item Part Description Quantity Note— 341726 3-ft GUN BAR, aluminum, 1.25-in. OD, assembly 1

1 248669 � BODY, adjustable mounting 1

2 327733 � SLEEVE, locking, 1.25-in. diameter 1

3 - - - - - - � CAP, plug 1

4 327732 � BODY, locking, 1.25-in. diameter 1

5 327703 � ROD, adjusting, aluminum, 1.25-in. OD x 3 ft 1


7 983061 � WASHER, flat, e, 0.406 x 0.812 x 0.065 in.,zinc

1


4-ft Gun Bar AssemblySee Figure 7-6.

Item Part Description Quantity Note— 341727 4-ft GUN BAR, aluminum, 1.25-in. OD, assembly 1

1 248669 � BODY, adjustable mounting 1

2 327733 � SLEEVE, locking, 1.25-in. diameter 1

3 - - - - - - � CAP, plug 1

4 327732 � BODY, locking, 1.25-in. diameter 1

5 327704 � ROD, adjusting, aluminum, 1.25-in. OD x 4 ft 1


7 983061 � WASHER, flat, e, 0.406 x 0.812 x 0.065 in.,zinc

1


Parts7-12


Powder Feed Hose Support Bracket KitSee Figure 7-6. Use this kit to prevent the powder feed hose from kinkingat the end of the gun bar.

Item Part Description Quantity Note— 1016163 KIT, bracket, tubing support, bar mount 1

9 301841 � STRAP, hook and loop tape, with buckle, 25 x3 cm

1

10 327973 � BRACKET, tubing support, bar mount 1

1

2

3

4

8

6

7

5

910

Figure 7-6 Bar-Mount Gun Mounting Assemblies and Powder Feed Hose Support Bracket Kit

Service Kits

Cable Kits

Part Description Note327734 8-METER CABLE, Sure Coat automatic

327735 12-METER CABLE, Sure Coat automatic



Parts 7-13


Hose Connector KitsSee Figure 7-7. Order the appropriate hose connector kit based on the sizeof powder feed hose in your system.

11-mm Hose Connector Kit

Item Part Description Quantity Note— 1013967 11-mm HOSE CONNECTOR, barb with nut 1

1 1010725 � NUT, connector, hose 1

2 1010724 � CONNECTOR, hose, barb, 11 mm 1


1/2-in. Hose Connector Kit

Item Part Description Quantity Note— 1013968 1/2-in. HOSE CONNECTOR, barb with nut 1

1 1010725 � NUT, connector, hose 1

2 1010726 � CONNECTOR, hose, barb, 1/2 in. 1


31

2

Figure 7-7 Hose Connector Kits

Parts7-14


O-ring Service KitSee Figure 7-8. This kit contains all O-rings in the spray gun.

Item Part Description Quantity Note— 1010753 SERVICE KIT, O-rings, Sure Coat automatic gun 1



3 940203 � O-RING, silicone, 0.875 x 1.00 x 0.063 in. 5 A

4 940060 � O-RING, Viton, 0.125 x 0.25 x 0.063 in. 10



7 1020466 � O-RING, PUR, 0.625 x 0.75 x 0.063 in.,70 duro

5

8 340637 � O-RING, PUR, 0.562 x 0.687 x 0.062 in. 10

NS 941205 � O-RING, silicone, 1.00 x 1.188 x 0.094 in. 5 B

NOTE A: This O-ring installs into the bar-mount gun inlet connector body.

B: This O-ring is not accessible in the spray gun. When you replace the spray gun O-rings, do not use thisO-ring.

NS: Not Shown

Parts 7-15


1

5

4

3

4

7

8

6

2

Figure 7-8 O-ring Service Kit

Note: Tube-mount gun shown. The bar-mount gun uses the same O-rings in the same locations.

Parts7-16


Options 8-1


Section 8Options

Options List The following table lists the options available for the Sure Coat automaticpowder spray gun. The following pages include parts lists, illustrations, andinstallation instructions, as required.

Part Description Note1089869 COVER, cord connection, Sure Coat D

1053242 FITTING, quick disconnect, female

1053256 FITTING, quick disconnect, male

1057390 HANGER, hose

1056575 SEAL, tube, coupling, silicone

1012985 EXTENSION, spray, 90 degree

1014077 CORNER SPRAY NOZZLE, 45 degree

1016353 IN-LINE NOZZLE, 45 degree, flat spray

1065059 NOZZLE, Sure Coat, 9 mm, open C1031738 NOZZLE, 50 degree, conical, Sure Coat auto1038359 NOZZLE, flat spray, 13 mm, 3 mm

341762 ION COLLECTOR, kit, tube-mount gun

189482 ION COLLECTOR, rod, bar-mount gun

1029201 TRAINING GUIDE, Sure Coat automatic gun A

1030482 PARTS POSTER, Sure Coat automatic gun B

NOTE A: This is a spiral-bound training manual that uses full-color photographs to show basic operation,maintenance, troubleshooting, disassembly, and assembly.

B: This is a laminated, 11 x 17-inch full-color exploded-view photograph of the gun with individual gun partslabeled with part numbers.

C: This nozzle is used for select European applications.

D: Use to cover cable connectors and isolate from ground.

UnassembledAssembled

Figure 8-1 Connector Cover

Options8-2


Quick-Disconnect Fittings and Components

Quick-Disconnect Parts See Figure 8-2.

Two hose connector/powder feed hose assemblies are used for each spraygun in a quick color change system: one for light-colored powders and onefor dark-colored powders.

Refer to Quick Disconnect Fitting Installation on the following page forinstructions.

Item Part Description Quantity Note6 1053256 FITTING, quick disconnect, male 1 A

7 1053242 FITTING, quick disconnect, female 1 B

8 1057390 HANGER, hose 1 B

NS 1056575 SEAL, tube, coupling, silicone 1 C

NOTE A: Order one fitting per spray gun.

B: Order two female fittings and two hose hangers per spray gun.

C: Repair part, replaces seal in female fitting.

NS: Not Shown

3

5

1

2

4

Standard Fittings Quick-Disconnect Fittings

8

6

2

7

9

Figure 8-2 Quick-Disconnect Fittings for Fast Color Change

1. Hose connector body2. Hose hanger bracket3. Nut

4. Hose connector/powder feed hoseassembly

5. Hose hanger bracket fitting6. Male quick-disconnect hose

connector body

7. Female quick-disconnectfitting

8. Quick-disconnect hosehanger brackets

9. Metal tab

Options 8-3


Quick-Disconnect Fitting Installation See Figure 8-2.

Removing Standard Fittings 1. Unscrew the old hose connector body (1) from the spray gun.

2. Remove the hose connector assemblies (4) and nuts (3) from the lightand dark hoses.

3. Remove the screws securing the hose hangers (5) to the hose hangerbrackets. Remove the standard hose hangers. Save the screws for thenew hose hangers.

Installing Quick-Disconnect Fittings


1. Thread the male quick-disconnect fitting (6) onto the spray gun.

2. Push the barbed end of the female quick-disconnect fittings (7) into thelight and dark hoses.

3. Install the hose hangers (8) on the hose hanger brackets with thescrews used on the standard hangers.

Using the Quick-Disconnect Fittings To connect a hose to the spray gun, push the female quick disconnect fittingonto the male quick disconnect fitting. You will hear a click as the femalefitting locks in place.

Push the other hose fitting onto the appropriate hose hanger bracket. It willclick as it locks in place.

To disconnect the hose from the spray gun or hose hanger, press the metaltab (9) on the top of the female fitting.

Options8-4


90-Degree Spray Extension The 90-degree spray extension allows powder to be sprayed at right anglesto the gun mounting orientation.

The extension ships with one 4-mm flat-spray nozzle. The standard 2.5-mmflat-spray nozzle shipped with the spray gun, or the optional 3-mm flat spraynozzle, can also be used with the extension. When the extension isinstalled on the spray gun, it replaces the standard nozzle nut and electrodesupport.

NOTE: The kit comes with instructions for installing, maintaining, andrepairing the extension.

See Figure 8-3.

Item Part Description Quantity Note— 1012985 EXTENSION, spray, 90 degree 1

1 1093572 � KIT, support, electrode, heavy duty 1

2 - - - - - - � � SUPPORT, electrode, gun 1

3 - - - - - - � � CONTACT, wire, electrode 1

4 941162 � � O-RING, silicone, 0.750 x 0.937 x 0.094 in. 1

5 940163 � � O-RING, silicone, 0.625 x 0.750 x 0.063 in. 2

6 1012992 � ELECTRODE, spring contact, 0.094 in.diameter

1

7 1012989 � HOLDER, electrode, horizontal 1


9 1012987 � ADAPTER, extension, 90 degree 1


11 1005028 � NUT, lock, nozzle 1

12 1012988 � BODY, extension, 90 degree 1

13 1012997 � ELECTRODE, 20-megohm resistor, packaged 1



16 1012990 � ADAPTER, electrode connection 1

17 1012994 � ELECTRODE, spring contact, 0.086 in.diameter

1

18 1012993 � HOLDER, electrode, vertical 1

19 1010661 � NOZZLE, 4 mm, flat spray, 13-mm ID 1

20 1012996 � NUT, nozzle, spray extension 1

NS 245733 DIELECTRIC GREASE, 3-cc applicator,(box of 12)

1 A

NS 1010662 NOZZLE, flat spray, 13-mm ID, 2.5 mm 1 ANS 1038359 NOZZLE, flat spray, 13-mm ID, 3 mm

NOTE A: Standard nozzle shipped with spray gun. Can also be ordered separately as replacement part.

B: Optional nozzle, order separately.

NS: Not Shown

Options 8-5


16

1514

13

12

1110

9

8

7

54

2

3

1

6

15

17

18

19

20

Figure 8-3 90-Degree Spray Extension

Options8-6


Optional Nozzles The following optional nozzles are installed on the spray gun with thestandard nozzle nut.

45-Degree Corner-Spray NozzleSpray Pattern Wide fan pattern perpendicular to the spray gun axis

Slot Type Angled, cross slot

Application Flanges and recesses

Part Description Note1014077 CORNER SPRAY NOZZLE, 45 degree

Figure 8-4 45-Degree Corner-Spray Nozzle

45-Degree In-Line Flat-Spray Nozzle Spray Pattern Narrow fan pattern in-line with spray gun axis

Slot Type Three angled slots in-line with spray gun axis

Application Top and bottom coating; typically no in/out part positioning

Part Description Note1016353 IN-LINE NOZZLE, 45 degree, flat spray

Figure 8-5 45-Degree In-Line Flat-Spray Nozzle

Options 8-7


9-mm Open Nozzle See Figure 8-6. This nozzle is used for specialized applications.

Part Description Note1065059 NOZZLE, Sure Coat, 9 mm, open

50-Degree Conical Nozzle See Figure 8-6.

Part Description Note1031738 NOZZLE, 50 degree, conical, Sure Coat, auto

Flat Spray Nozzles See Figure 8-6.

Part Description Note1010662 NOZZLE, flat spray, 13-mm ID, 2.5 mm

1038359 NOZZLE, flat spray, 13 mm ID, 3 mm

1010661 NOZZLE, flat spray, 13-mm ID, 4 mm

9-mm Open Nozzle 50-Degree Conical Nozzle Flat Spray Nozzles

Figure 8-6 Open, Conical, and Flat Spray Nozzles

Options8-8


Ion Collector Kits

Tube-Mount Gun Ion Collector Kit

Item Part Description Quantity Note— 341762 KIT, ion collector kit, tube mount 1

1 982098 � SCREW, flat, slotted, M4 x 6, zinc 1

2 982067 � SCREW, set, cup, M5 x 5, black 1

3 - - - - - - � BRACKET, ion collector, tube mount 1

4 189482 � ROD, ion collector, 11 in. 1

32

1

4

Figure 8-7 Tube-Mount Gun Ion Collector Kit

Bar-Mount Gun Ion Collector Kit

Item Part Description Quantity Note1 189482 ROD, ion collector, 11 in.

1

Figure 8-8 Bar-Mount Gun Ion Collector Kit

sure coat automatic powder spray gun -...

Documents