Nordson Kinetix 334593-04 Reference guide

KinetixrElectrostatic Spray Gun
Automatic Air-Assisted Airless
Customer Product Manual
Part 334593-04
Issued 6/19
NORDSON CORPORATION •AMHERST, OHIO •USA
C
APPROVED
US
FM
For parts and technical support, call the Industrial Coating
Systems Customer Support Center at [phone] or
contact your local Nordson representative.
This document is subject to change without notice.
Check http://emanuals.nordson.com for the latest version.

Part 334593-04 E2019 Nordson Corporation
Contact Us
Nordson Corporation welcomes requests for information, comments, and
inquiries about its products. General information about Nordson can be
found on the Internet using the following address:
http://www.nordson.com.
Address all correspondence to:
Nordson Corporation
Attn: Customer Service
555 Jackson Street
Amherst, OH 44001
Notice
This is a Nordson Corporation publication which is protected by copyright.
Original copyright date 2000. No part of this document may be
photocopied, reproduced, or translated to another language without the
prior written consent of Nordson Corporation. The information contained
in this publication is subject to change without notice.
Trademarks
Cross-Cut, Kinetix, Nordson, and the Nordson logo are registered
trademarks of Nordson Corporation.
Loctite is a registered trademark of Loctite Corporation.
MagnaLube is a registered trademark of General Magnaplate Corporation.
Perlast is a trademark of Precision Polymer Engineering Limited.
Viton is a registered trademark of E. I. DuPont de Nemours and Company.

Table of Contents i
Part 334593-04
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Table of Contents
Safety 1-1..................................................
Introduction 1-1.............................................
Qualified Personnel 1-1......................................
Intended Use 1-1............................................
Regulations and Approvals 1-2................................
Personal Safety 1-2.........................................
High-Pressure Fluids 1-3...................................
Fire Safety 1-4..............................................
Halogenated Hydrocarbon Solvent Hazards 1-4...............
Action in the Event of a Malfunction 1-5........................
Disposal 1-5................................................
Safety Label 1-5............................................
Description 2-1.............................................
Introduction 2-1.............................................
Air-Assisted Airless Description 2-2............................
Features 2-2................................................
Options 2-2.................................................
Coating Materials 2-2........................................
Theory of Operation 2-3.....................................
Electrostatic Charge 2-3...................................
Fluid Flow 2-3............................................
Air Flow 2-4..............................................
Installation 3-1.............................................
Preparation 3-1.............................................
Typical Air-Assisted Airless System 3-2........................
Air and Fluid Hose Connections 3-3............................
Air Hose 3-3..............................................
Fluid Hose 3-3............................................
Fluid Hose Connections 3-4..............................
Gun Cable 3-6..............................................
Securing the Hoses and Cables 3-7............................
Gun Cable 3-7............................................
Air and Fluid Hoses 3-7....................................
Installing the Nozzle and Gasket with Restrictor 3-7..............
Optional Quick-Exhaust Valve 3-9.............................
Operation 4-1..............................................
Introduction 4-1.............................................
Daily Startup 4-2............................................
Spray Pattern and Atomization Adjustments 4-2.................
Shutdown 4-3...............................................
Short-Term 4-3...........................................
Long-Term 4-3............................................
Multi-Component Coatings 4-3..............................

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Maintenance 5-1...........................................
Introduction 5-1.............................................
Daily 5-1...................................................
Periodically 5-2.............................................
System Flushing 5-3......................................
Spray Gun Cleaning 5-3...................................
Routine Cleaning 5-3....................................
Extensive Cleaning 5-4..................................
Electrostatic System Checks 5-4..............................
Troubleshooting 6-1........................................
Introduction 6-1.............................................
Common Problems 6-2.......................................
Spray Pattern/Film Build Troubleshooting 6-3...................
Electrostatic Troubleshooting 6-4..............................
Multiplier Continuity and Resistance Check 6-5..................
Gun Cable Continuity Checks 6-6.............................
Repair 7-1.................................................
Tools/Supplies Required 7-2..................................
Nozzle, Restrictor, and Fluid Tip Replacement 7-3...............
Return Springs Replacement 7-4.............................
Air Piston and Connecting Rod Replacement 7-6................
Preparation 7-6...........................................
Spray Gun Disassembly 7-6................................
Air Piston and Connecting Rod Replacement 7-6.............
Spray Gun Assembly 7-7..................................
Ball Tip and Packing Cartridge Replacement 7-8................
Preparation 7-9...........................................
Spray Gun Disassembly 7-9................................
Ball Tip and Packing Cartridge Removal 7-9.................
Ball Tip and Packing Cartridge Installation 7-11................
Spray Gun Assembly 7-11..................................
Multiplier Replacement 7-12...................................
Multiplier Removal 7-12....................................
Multiplier Installation 7-13...................................
Gun Cable Replacement 7-14..................................
Fluid Supply Hose Replacement 7-15...........................
Hose Removal 7-15........................................
Hose Installation 7-15......................................
Service Illustration and Notes 7-16.............................

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Parts 8-1...................................................
Introduction 8-1.............................................
Using the Illustrated Parts List 8-1..........................
Spray Gun Parts 8-2........................................
Adhesives, Sealants, and Lubricants 8-6.......................
Recommended Kits 8-6......................................
Perlast Fluid Seal 8-6.....................................
Fluid Tip 8-6..............................................
Air Seal 8-6..............................................
Packing Cartridge 8-7.....................................
Puller Link Upgrade Kits 8-7...............................
Puller Link Upgrade with Spacer Block 8-7................
Puller Link Upgrade 8-7................................
Cordset Assemblies 8-7...................................
Standard 1.5 ft Gun Cordset 8-7.........................
Automatic Cordset with 50-ft Extension 8-8................
Optional Quick-Exhaust Valve 8-8.............................
Optional Hotpaint Fluid Seal Kit 8-8............................
Optional PTFE Packing Cartridge 8-9..........................
Hoses and Tubing 8-9........................................
Recommended Spare Parts 8-10...............................
Specifications 9-1..........................................
Dimensions 9-1.............................................
Weight 9-1.................................................
Operating Pressures 9-1.....................................
Air Hose Requirements 9-1...................................
Standard Fitting Sizes 9-2....................................
Gun Electrostatics 9-2.......................................
Conductivity Range 9-2....................................
Approvals 9-2...............................................
Special Conditions for Safe Use in the European Union 9-2....

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Part 334593-04 E2019 Nordson Corporation

Safety 1-1
Part 334593-04
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Section 1
Safety
Introduction
Read and follow these safety instructions. Task- and equipment-specific
warnings, cautions, and instructions are included in equipment
documentation where appropriate.
Make sure all equipment documentation, including these instructions, is
accessible to persons operating or servicing equipment.
Qualified Personnel
Equipment owners are responsible for making sure that Nordson equipment
is installed, operated, and serviced by qualified personnel. Qualified
personnel are those employees or contractors who are trained to safely
perform their assigned tasks. They are familiar with all relevant safety rules
and regulations and are physically capable of performing their assigned
tasks.
Intended Use
Use of Nordson equipment in ways other than those described in the
documentation supplied with the equipment may result in injury to persons
or damage to property.
Some examples of unintended use of equipment include
Susing incompatible materials
Smaking unauthorized modifications
Sremoving or bypassing safety guards or interlocks
Susing incompatible or damaged parts
Susing unapproved auxiliary equipment
Soperating equipment in excess of maximum ratings

Safety
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Part 334593-04 E2019 Nordson Corporation
Regulations and Approvals
Make sure all equipment is rated and approved for the environment in which
it is used. Any approvals obtained for Nordson equipment will be voided if
instructions for installation, operation, and service are not followed.
Personal Safety
To prevent injury follow these instructions.
SDo not operate or service equipment unless you are qualified.
SDo not operate equipment unless safety guards, doors, or covers are
intact and automatic interlocks are operating properly. Do not bypass or
disarm any safety devices.
SKeep clear of moving equipment. Before adjusting or servicing moving
equipment, shut off the power supply and wait until the equipment
comes to a complete stop. Lock out power and secure the equipment to
prevent unexpected movement.
SRelieve (bleed off) hydraulic and pneumatic pressure before adjusting or
servicing pressurized systems or components. Disconnect, lock out,
and tag switches before servicing electrical equipment.
SWhile operating manual spray guns, make sure you are grounded.
Wear electrically conductive gloves or a grounding strap connected to
the gun handle or other true earth ground. Do not wear or carry metallic
objects such as jewelry or tools.
SIf you receive even a slight electrical shock, shut down all electrical or
electrostatic equipment immediately. Do not restart the equipment until
the problem has been identified and corrected.
SObtain and read Material Safety Data Sheets (MSDS) for all materials
used. Follow the manufacturer’s instructions for safe handling and use
of materials, and use recommended personal protection devices.
SMake sure the spray area is adequately ventilated.
STo prevent injury, be aware of less-obvious dangers in the workplace
that often cannot be completely eliminated, such as hot surfaces, sharp
edges, energized electrical circuits, and moving parts that cannot be
enclosed or otherwise guarded for practical reasons.

Safety 1-3
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High-Pressure Fluids
High-pressure fluids, unless they are safely contained, are extremely
hazardous. Always relieve fluid pressure before adjusting or servicing high
pressure equipment. A jet of high-pressure fluid can cut like a knife and
cause serious bodily injury, amputation, or death. Fluids penetrating the
skin can also cause toxic poisoning.
If you suffer a fluid injection injury, seek medical care immediately. If
possible, provide a copy of the MSDS for the injected fluid to the health care
provider.
The National Spray Equipment Manufacturers Association has created a
wallet card that you should carry when you are operating high-pressure
spray equipment. These cards are supplied with your equipment. The
following is the text of this card:
WARNING: Any injury caused by high pressure liquid can be serious. If
you are injured or even suspect an injury:
SGo to an emergency room immediately.
STell the doctor that you suspect an injection injury.
SShow them this card
STell them what kind of material you were spraying
MEDICAL ALERT—AIRLESS SPRAY WOUNDS: NOTE TO PHYSICIAN
Injection in the skin is a serious traumatic injury. It is important to treat the
injury surgically as soon as possible. Do not delay treatment to research
toxicity. Toxicity is a concern with some exotic coatings injected directly into
the bloodstream.
Consultation with a plastic surgeon or a reconstructive hand surgeon may
be advisable.
The seriousness of the wound depends on where the injury is on the body,
whether the substance hit something on its way in and deflected causing
more damage, and many other variables including skin microflora residing
in the paint or gun which are blasted into the wound. If the injected paint
contains acrylic latex and titanium dioxide that damage the tissue’s
resistance to infection, bacterial growth will flourish. The treatment that
doctors recommend for an injection injury to the hand includes immediate
decompression of the closed vascular compartments of the hand to release
the underlying tissue distended by the injected paint, judicious wound
debridement, and immediate antibiotic treatment.

Safety
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Part 334593-04 E2019 Nordson Corporation
Fire Safety
To avoid a fire or explosion, follow these instructions.
SGround all conductive equipment. Use only grounded air and fluid
hoses. Check equipment and workpiece grounding devices regularly.
Resistance to ground must not exceed one megohm.
SShut down all equipment immediately if you notice static sparking or
arcing. Do not restart the equipment until the cause has been identified
and corrected.
SDo not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
SDo not heat materials to temperatures above those recommended by
the manufacturer. Make sure heat monitoring and limiting devices are
working properly.
SProvide adequate ventilation to prevent dangerous concentrations of
volatile particles or vapors. Refer to local codes or your material MSDS
for guidance.
SDo not disconnect live electrical circuits when working with flammable
materials. Shut off power at a disconnect switch first to prevent
sparking.
SKnow where emergency stop buttons, shutoff valves, and fire
extinguishers are located. If a fire starts in a spray booth, immediately
shut off the spray system and exhaust fans.
SShut off electrostatic power and ground the charging system before
adjusting, cleaning, or repairing electrostatic equipment.
SClean, maintain, test, and repair equipment according to the instructions
in your equipment documentation.
SUse only replacement parts that are designed for use with original
equipment. Contact your Nordson representative for parts information
and advice.
Halogenated Hydrocarbon Solvent Hazards
Do not use halogenated hydrocarbon solvents in a pressurized system that
contains aluminum components. Under pressure, these solvents can react
with aluminum and explode, causing injury, death, or property damage.
Halogenated hydrocarbon solvents contain one or more of the following
elements:
Element Symbol Prefix
Fluorine F “Fluoro-”
Chlorine Cl “Chloro-”
Bromine Br “Bromo-”
Iodine I “Iodo-”
Check your material MSDS or contact your material supplier for more
information. If you must use halogenated hydrocarbon solvents, contact
your Nordson representative for information about compatible Nordson
components.

Safety 1-5
Part 334593-04
E2019 Nordson Corporation
Action in the Event of a Malfunction
If a system or any equipment in a system malfunctions, shut off the system
immediately and perform the following steps:
SDisconnect and lock out system electrical power. Close hydraulic and
pneumatic shutoff valves and relieve pressures.
SIdentify the reason for the malfunction and correct it before restarting the
system.
Disposal
Dispose of equipment and materials used in operation and servicing
according to local codes.
Safety Label
Table 1-1 contains the text of the safety label on this equipment. The safety
label is provided to help you operate and maintain your equipment safely.
See Figure 2-1 for the location of the safety label.
Table 1-1 Safety Label
Heading
WARNING: Allow only qualified personnel to use this equipment.
Observe and follow all safety instructions for this equipment.
WARNING: Risk of explosion or fire. Fire, open flames, and
smoking prohibited.
WARNING: Do not point the spray gun at any part of your body or
at anyone else. Do not operate the fluid delivery system if any
component is leaking. Failure to observe this warning could result
in an injection injury.
WARNING: Risk of electrical shock. Disconnect and lockout input
power to equipment before servicing. Failure to observe this
warning may result in personal injury or death.

Safety
1-6
Part 334593-04 E2019 Nordson Corporation

Description 2-1
Part 334593-04
E2019 Nordson Corporation
Section 2
Description
Introduction
See Figure 2-1.
This Kinetix air-assisted airless (AAA) automatic electrostatic spray gun
electrostatically charges and sprays liquid coatings. The spray gun is
powered by a separate gun control unit and has a user-replaceable internal
voltage multiplier.
The spray gun is non-circulating and can be used with heated and unheated
non-circulating spray systems.
WARNING
Maximum Fluid Pressure
103 Bar (1500 PSI)
Figure 2-1 Kinetix Air-Assisted Airless Automatic Electrostatic Spray Gun
Note: Refer to Safety Label on page 1-5 for a description of the warning symbols.

Description
2-2
Part 334593-04 E2019 Nordson Corporation
Air-Assisted Airless Description
This gun sprays coating materials at high pressures of up to
103 bar (1500 psi). Atomization is achieved by forcing the coating materials
through a very small nozzle orifice. This spray gun can yield considerably
better transfer efficiencies than conventional air spray systems and can
apply large quantities of coating material very quickly.
Air-assisted airless spray guns use atomizing air to help atomize and shape
the coating materials as it exits the nozzle. The atomization air allows the
spray gun to operate at lower fluid pressures than airless spray guns. The
lower fluid pressures allow a softer spray with higher transfer efficiencies.
Air-assisted airless spray guns are particularly good at eliminating the tails
often seen in some airless applications.
Features
Features of the air-assisted airless spray gun are:
Seasy disassembly for cleaning and repair
Slightweight, compact
Sself-adjusting packing cartridge
Options
Options include a variety of Nordson Cross-Cutrand dome nozzles;
restrictors; fluid hoses; quick-exhaust valve; and fittings.
Coating Materials
The spray gun is compatible with a wide variety of coating materials
including
Sgeneral solvent-based
Smetallics
Shigh-solids
Smulti-component
NOTE: The seals in the spray gun are compatible with most coatings. If
the coating material you use damages the seals, contact your Nordson
Corporation representative for compatible replacements.

Description 2-3
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Theory of Operation
See Figure 2-2.
Electrostatic Charge
The gun control unit delivers low-voltage dc power through an electrostatic
cable (1) to the multiplier (3), which is housed in the extension (4) of the
spray gun. The multiplier then generates high-voltage for an electrostatic
field. This electrostatic field produces a corona discharge around the gun’s
electrode (6).
Resistors within the multiplier limit the output current at safe levels.
High-voltage (93 kV) passes through the spray gun electrode to
electrostatically charge the coating material. As the charged coating
material is sprayed it is attracted to the grounded object to be coated.
Fluid Flow
Fluid enters the spray gun through a fluid hose (9) attached to the extension
and flows to the fluid tip (7). The ball tip (5) controls fluid flow through the
fluid tip. The packing cartridge (8) prevents fluid from flowing out of the
back of the extension.
1
2
4
9
11
3
6
5
7
8
12
Electrostatic flow
Air flow
Fluid flow
10
Figure 2-2 Spray Gun Components and Operation
1. Electrostatic cable
2. Gun body
3. Multiplier
4. Extension
5. Ball tip assembly
6. Electrode
7. Fluid tip
8. Packing cartridge assembly
9. Fluid hose
10. Atomization air core
11. Activation (trigger) air inlet fitting
12. Air piston

Description
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Part 334593-04 E2019 Nordson Corporation
Air Flow
Air enters the spray gun body at two fittings:
Activation (trigger) — Activation or trigger air (11) moves the air piston (12),
which then opens the atomization air valve and develops full atomization air
flow. The air piston then pulls on the connecting rod, opening the ball tip
assembly (5) generating fluid flow. There is always maximum air flow prior
to fluid flow thus eliminating fluid spitting and poor atomization of the initial
fluid flow.
Atomization — Atomization air (10) triggers on when the spray gun is
activated or triggered. A small amount of atomization air continually flows
through the spray gun body. The atomization air helps atomize and shape
the coating material as it exits the nozzle.
Air-assisted airless spray guns can be fitted with a variety of restrictors and
nozzles. Restrictors are pre-atomization devices that do not normally
reduce flow, but aid in atomization and tend to reduce the pattern width. If a
restrictor is used, the nozzle gasket is removed and replaced with a
restrictor.

Installation 3-1
Part 334593-04
E2019 Nordson Corporation
Section 3
Installation
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
Preparation
CAUTION: Do not overtighten parts. Failure to observe this caution will
result in equipment damage.
NOTE: Nozzles; gaskets or gasket with restrictors; the electrode; and the
PTFE retaining washer are not shipped with the spray gun and must be
ordered separately based on your application.
NOTE: A gasket or gasket with restrictor and the PTFE retaining washer
are required. For assistance in selecting the appropriate nozzle and
restrictor for your application, contact your Nordson Corporation
representative.
Before installation,
Smake sure you have the appropriate nozzle; gasket or gasket with
restrictor; electrode; and PTFE retaining washer for your application.
Smake sure you have high-pressure fluid hoses of the correct length, ID,
and materials.
WARNING: Risk of fire and/or electrical shock if the spray gun and the
system components are not properly grounded.
Smake sure the system is properly grounded.
NOTE: Inadequately grounded parts will lose electrostatic attraction when
sprayed.
Sremove the spray gun, brushes, and combination tool from the box.

Installation
3-2
Part 334593-04 E2019 Nordson Corporation
Typical Air-Assisted Airless System
WARNING: Install an approved pressure-relief device set at 103 bar
(1500 psi) in the fluid line to the spray gun. The fluid supply hose must
have a minimum pressure rating of 103 bar (1500 psi). Failure to observe
this warning could result in equipment damage or personal injury.
Figure 3-1 shows the components of a typical system. Some components
shown are optional. Make sure your system contains self-relieving shutoff
valves for the fluid supply.
1
34
5 6 7 8 9
12 7 8 9
13
10
15
14
11
7 8 9
16
2
17 18
Figure 3-1 Typical Air-Assisted Airless System
1. Spray gun
2. Control unit
3. Fluid filter
4. Heater (as required)
5. Pump
6. Air lubricator
7. Air regulator
8. Air filter
9. Self-relieving shutoff valve
10. Drain valve
11. Drain rod
12. Solenoid
13. Siphon screen
14. Activation (trigger) air
15. Fluid supply
16. Atomizing air
17. Gun cable
18. Extension cable

Installation 3-3
Part 334593-04
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Air and Fluid Hose Connections
Spray gun fittings accept standard Nordson fluid hoses.
Air Hose
The air hoses supplying air to the spray gun should be no longer than
7.62 m (25 ft). The atomizing air hoses should have a minimum
6.4-mm (1/4-in.) ID.
Limit the number of restrictions in the air supply lines and hose to provide
maximum air flow.
1. Clean the air hose fitting with a clean, dry cloth.
2. Connect the atomization air hose between the 3/8-in. tube fitting in the
spray gun body and the air supply outlet.
3. Connect the trigger air hose between the 1/4-in. tube fitting in the spray
gun body and the air supply outlet.
Fluid Hose
WARNING: The fluid hose must be a grounding-type hose, with continuity
between fittings. Without a ground, a static charge could build up in the
spray gun, resulting in shocks to the operator or sparking that could cause a
fire. Resistance checks, from hose fitting to hose fitting, should be a part of
your regular maintenance procedures.
Table 3-1 Example of a 20 μΑ Current Draw
Resistivity of Coating Isocore Hose (1/4-in. ID)
0.05 MΩ16.5 ft
0.10 MΩ3.5 ft
As coating materials become more conductive (lower resistivity) more
current will bleed back through the fluid column in the fluid hose to the
grounded fitting. With a very conductive material like water, all of the
current will bleed to the ground and the spray gun would essentially be
shorted.
A certain level of conductivity is required for electrostatics to be practical.
Coating materials with resistivities of 0.75−2.0 MΩ usually work well. The
transfer efficiency and wrap could be reduced as coating resistivities fall
below 0.10 MΩ.
Figure 3-2 identifies the optimum coating resistivities for electrostatics of
0.75−2.0 MΩ.
Figure 3-3 plots the tubing length required to keep current draw at 20 μA.
To maintain current draw at 20 μA the hose length must increase.

Installation
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Best range for airspray electrostatic 0.5−3.0 range — A to E scale.
Legend:
Best range for rotary 0.10−1.0 range — C to F scale.
Best range for airless and air−assisted airless electrostatic
0.75−2.0 range — B to D scale.
NOTE: Readings outside these ranges are often acceptable.
−
−
−
MEG-OHM METER
AB
E
D
F
Non-polar
(Non-conductive)
Polar
(Conductive)
C
PAINT RESISTIVITY METER
LOW HIGH
Figure 3-2 Resistivity Range for Coatings
Fluid Hose Connections
1. Clean the fluid hose fittings with a clean, dry cloth.
2. Connect the fluid hose(s) between the fluid-delivery system outlet and
the fluid line on the spray gun extension.
NOTE: The standard fluid hose will work well for most coating materials.
The effectiveness of the electrostatics may diminish when coating
resistivities fall below 25 megohms/cm. The optional 25-ft long fluid hose
will improve the electrostatic charge by isolating the fluid column.