Nordson Tribomatic 500 User manual

Tribomaticr500 Manual Powder
Spray Gun
Customer Product Manual
Part 237467D02
Issued 11/07
NORDSON CORPORATION AMHERST, OHIO USA
For parts and technical support, call the Industrial Coating
Systems Customer Support Center at [phone] or
contact your local Nordson representative.
This document is subject to change without notice.
Check http://emanuals.nordson.com for the latest version.

Part 237467D02 E2007 Nordson Corporation
Table of Contents
Safety 1.......................................
Qualified Personnel 1.........................
Intended Use 1..............................
Regulations and Approvals 1..................
Personal Safety 2............................
Fire Safety 2................................
Grounding 3.................................
Action in the Event of a Malfunction 3...........
Disposal 3..................................
Description 4..................................
Gun Components and Operation 4.............
Specifications 5..............................
Installation 6..................................
Operation 8...................................
Break-In Period 8............................
Settings 8...................................
Pattern Control 9............................
MicroAmpere Display 9.......................
Maintenance 9................................
Troubleshooting 10.............................
Repair 12......................................
Inner and Outer Charge Sleeve Replacement 12..
Disassembly 12............................
Assembly 13...............................
Outer Charge Sleeve Support and
Pattern Adjust Sleeve Replacement 14..........
Handle, Trigger, and Cable Replacement 15......
Handle Disassembly 15.....................
Assembly 16...............................
Parts 17.......................................
Using the Illustrated Parts List 17...............
Gun Parts 18.................................
Inner Charge Sleeve Kit 20.....................
Outer Charge Sleeve Support Kit 20.............
Diffuser Kit 21................................
Handle Kit 21.................................
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 1997. 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
Tribomatic, Nordson and the Nordson logo are registered trademarks of
Nordson Corporation.
Viton is a registered trademark of E. I. DuPont de Nemours and Company.

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Tribomaticr500 Manual Powder Spray Gun
Safety
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 all persons operating or servicing equipment.
Qualified Personnel
Equipment owners are responsible for making sure that Nordson equipment
is installed, operated, and serviced by qualified personnel. Qualified
personnel are those employees or contractors who are trained to safely
perform their assigned tasks. They are familiar with all relevant safety rules
and regulations and are physically capable of performing their assigned
tasks.
Intended Use
Use of Nordson equipment in ways other than those described in the
documentation supplied with the equipment may result in injury to persons
or damage to property.
Some examples of unintended use of equipment include
Susing incompatible materials
Smaking unauthorized modifications
Sremoving or bypassing safety guards or interlocks
Susing incompatible or damaged parts
Susing unapproved auxiliary equipment
Soperating equipment in excess of maximum ratings
Regulations and Approvals
Make sure all equipment is rated and approved for the environment in which
it is used. Any approvals obtained for Nordson equipment will be voided if
instructions for installation, operation, and service are not followed.
All phases of equipment installation must comply with all federal, state, and
local codes.

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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 any
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.
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.
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.
Fire Safety
To avoid a fire or explosion, follow these instructions.
SDo not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
SProvide adequate ventilation to prevent dangerous concentrations of
volatile materials or vapors. Refer to local codes or your material MSDS
for guidance.
SDo not disconnect live electrical circuits while 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.
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.

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Grounding
WARNING: Operating faulty electrostatic equipment is hazardous and can
cause electrocution, fire, or explosion. Make resistance checks part of your
periodic maintenance program. If you receive even a slight electrical shock
or notice static sparking or arcing, shut down all electrical or electrostatic
equipment immediately. Do not restart the equipment until the problem has
been identified and corrected.
Grounding inside and around the booth openings must comply with NFPA
requirements for Class II Division 1 or 2 Hazardous Locations. Refer to
NFPA 33, NFPA 70 (NEC articles 500, 502, and 516), and NFPA 77, latest
conditions.
SAll electrically conductive objects in the spray areas shall be electrically
connected to ground with a resistance of not more than 1 megohm as
measured with an instrument that applies at least 500 volts to the circuit
being evaluated.
SEquipment to be grounded includes, but is not limited to, the floor of the
spray area, operator platforms, hoppers, photoeye supports, and
blow-off nozzles. Personnel working in the spray area must be
grounded.
SThere 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 must
wear shoes with conductive soles or use a ground strap to maintain a
connection to ground when working with or around electrostatic
equipment.
SOperators must maintain skin-to-handle contact between their hand and
the gun handle to prevent shocks while operating manual electrostatic
spray guns. If gloves must be worn, cut away the palm or fingers, wear
electrically conductive gloves, or wear a grounding strap connected to
the gun handle or other true earth ground.
SShut off electrostatic power supplies and ground gun electrodes before
making adjustments or cleaning powder spray guns.
SConnect all disconnected equipment, ground cables, and wires after
servicing equipment.
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 electrical power. Close pneumatic shutoff
valves and relieve pressures.
SIdentify the reason for the malfunction and correct it before restarting the
equipment.
Disposal
Dispose of equipment and materials used in operation and servicing
according to local codes.

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Description
See Figure 1. The Tribomatic 500 manual powder spray gun uses
compressed air to propel powder coatings through charging sleeves inside
the barrel of the gun. Friction electrostatically charges the powder particles
as they flow through the sleeves.
The 6 meter spray gun is used with a Nordson 3-gauge Tribomatic II control
unit and modular Tribomatic powder pump, which are sold separately.
Figure 1 Tribomatic 500 Manual Powder Spray Gun
Gun Components and Operation
See Figure 2. The diffuser (3) mixes compressed air (1) with the powder (2)
before it enters the charging sleeves. As the powder and air mixture flows
between the inner (4) and outer (5) charging sleeves, the powder particles
collide with the charge sleeve walls and receive an electrostatic charge.
The sleeves receive an opposite charge that is grounded through the cable
(9) and control unit. The control unit displays the grounded charge in
microamperes of current. The gun’s current output indicates the charge
received by the powder.
NOTE: The strength of the charge the powder receives will vary depending
on many factors, including the powder type and velocity.
The deflector (7) and the pattern adjust sleeve (8) control the spray pattern
shape. Sliding the pattern adjust sleeve forward narrows the pattern; sliding
it back widens the pattern.

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Figure 2 Cutaway View −Gun Components and Operation
1. Air
2. Powder
3. Diffuser
4. Inner charge sleeve
5. Outer charge sleeve
6. Pattern adjuster retainer
7. Deflector
8. Pattern adjust sleeve
9. Cable
Specifications
Length: 521 mm (20.5 in.) maximum
Weight: 0.5 kg (1.1 lbs) (without cable)
Capacity: 4.5−8 kg (10−18 lbs) per hour

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Installation
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
WARNING: Ground all electrically conductive equipment in the spray area.
Ungrounded or poorly grounded equipment can store an electrostatic
charge that can give personnel a serve shock or arc and cause a fire or
explosion.
1. See Figure 3. The gun is shipped with the cable (8) installed. Connect
the cable end to the GUN OUTPUT receptacle (3) on the back of the
Tribomatic II control unit.
2. Install black 6-mm air tubing (11) between the flow-rate air fitting (2) on
the control unit and the fitting on the powder pump (10).
3. Install blue 6-mm air tubing (4) between the diffuser air fitting (1) on the
control unit and the diffuser (5).
4. Install 9-mm (3/8-in.) ID powder feed hose (9) between the powder pump
and the diffuser. Install a few inches of spiral-cut tubing (6) on the feed
hose at the diffuser and pump connection points. Secure the spiral-cut
tubing with a clamp (7). The tubing will prevent the hose from kinking
and blocking the flow of powder.
5. Bundle the powder feed hose, diffuser air tubing, and trigger cable
together with spiral-cut plastic tubing. To prevent damage to the hose,
tubing, and cable, keep them away from moving equipment and off the
floor.

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5
Figure 3 Gun Connections
1. Diffuser air fitting
2. Flow-rate air fitting
3. GUN OUTPUT receptacle
4. Blue 6-mm air tubing
5. Diffuser
6. Spiral-cut tubing
7. Clamps
8. Cable
9. Powder feed hose
10. Powder pump
11. Black 6-mm air tubing

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Operation
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
WARNING: This equipment can be dangerous unless it is used in
accordance with the rules laid down in this manual.
WARNING: The operator must maintain skin contact with the gun handle
during operation. If wearing gloves, either cut away the palm or wear
conductive gloves. Failure to observe this warning may result in a severe
shock.
Break-In Period
Break in new guns before using them for production. The break-in process
allows the electrostatic charge generated in the sleeves time to establish a
path to ground. Powder charging will improve as the ground path becomes
firmly established.
Spray powder for 10 minutes, using the air pressure settings given in this
section, then hang up the gun for 1/2to 1 hour. You may hear a slight
popping sound from the gun.
When you disassemble the gun for cleaning or repairs, you may see small
black marks (carbon tracking or tiny pinholes) on the outer charge sleeve,
where the sleeve contacts the metal support. This is normal, and will not
affect gun operation.
Settings
Set flow-rate and diffuser air pressures at the control unit. Refer to your
control unit manual for the location of the regulators.
Air pressure controls powder velocity, flow rate, atomization, and charging.
To start, set the regulators as follows:
Flow-rate air 2 bar (30 psi)
Diffuser air 1 bar (15 psi)
Adjust these pressures to obtain the desired results as follows:
SIncrease flow-rate air pressure to increase film build; decrease pressure
to decrease film build.
SIncrease diffuser air pressure to increase electrostatic charging.
Decrease diffuser pressure to decrease charging.

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Pattern Control
Move the pattern control sleeve back for a wide pattern, forward for a
narrow pattern.
MicroAmpere Display
The control unit display should show 1.4 to 4 microamperes during
operation. Gun current output varies depending on powder velocity, type of
powder, and compressed air moisture content. The higher the output, the
better the powder is charging.
Maintenance
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
Perform the following steps daily:
1. Remove the powder feed hose from the pump and the air tubing from
the diffuser. Make sure the booth exhaust fan is on. Point the gun into
the booth and insert a compressed-air blow gun into the end of the feed
hose. Blow out the feed hose, diffuser, and gun.
CAUTION: When cleaning, always disconnect the air tubing from the
diffuser and pump. Powder could travel through the air tubing and
contaminate the solenoid valves, regulators, and gauges in the control unit.
Always blow powder into the booth.
2. Disconnect the powder feed hose from the diffuser. Remove the diffuser
from the gun. Blow out the diffuser with low-pressure compressed air.
3. Remove the inner and outer charge sleeves from the gun. Clean the
sleeves and nozzle with low-pressure compressed air and a clean, soft
cloth. Refer to Repair for disassembly instructions.
CAUTION: Never use a knife or other sharp object that will scratch plastic
to clean the gun or pump parts. Powder particles will build up on scratches,
fuse together on impact, and clog the gun or pump.
4. Disassemble the powder pump and clean the parts with low-pressure
compressed air and a clean, soft cloth. Refer to the pump manual for
disassembly instructions.
5. Check all equipment ground connections. Make sure all equipment in
the spray area is connected to a true earth ground.

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Troubleshooting
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
These procedures cover only the most common problems that you may
encounter. If you cannot solve the problem with the information given here,
contact your local Nordson representative for help.
Problem Possible Cause Corrective Action
1. Powder does
not flow when
gun is triggered
No supply air or supply pressure set too
low
Make sure the control unit is getting
compressed air at correct pressure.
Flow-rate air pressure set too low Increase the flow-rate air pressure.
Blockage in system Check the flow-rate air tubing for kinks.
Make sure the powder feed hose, pump,
and pickup tube are not clogged. Make
sure the powder and compressed air
supplies are clean and dry. Check the
fluidizing air pressure.
Control unit malfunction: solenoid valve
not opening
Refer to the control unit manual.
2. Powder puffing
from gun
Blockage in system Clean the pickup tube, pump, feed hose,
diffuser, and gun. Make sure the
powder is not damp. Check the air
dryer.
Pump venturi throat worn Replace the venturi throat.
Diffuser air pressure too high, or
incorrect ratio of diffuser to flow-rate air
pressure
Decrease the diffuser air pressure or
increase the flow-rate air pressure.
Powder feed hose ID too large or hose
too short
Change to a smaller ID hose or change
the hose length. Best results are
obtained when the hose is 4−6 meters
(13−20 feet) long.

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Problem Possible Cause Corrective Action
3. Poor powder
charging—little
or no
electrostatic
wrap or
adhesion
Flow-rate air pressure too high or
diffuser air pressure too low
Decrease the flow-rate air pressure or
increase the diffuser air pressure.
Parts not properly grounded Check the conveyor and hanger
grounds with an ohm meter. The
resistance between the parts and
ground should not exceed 1 megohm.
For best results the resistance should
not exceed 500 ohms. Clean the
hangers and conveyor.
Gun not properly broken in Break in the gun according to
instructions in the Operation section.
Too much moisture in compressed air
supply
Check the air dryer for proper operation.
Use a refrigerated or regenerative
desiccant air dryer that can produce a
3.4 _C (38 _F) or lower dew point at
7 bar (100 psi). Drain the air filter and
check the filter element.
Inner and outer charge sleeves worn Disassemble the gun and replace the
sleeves. Refer to the Repair section.
Too many fine particles in powder supply Add virgin powder to the feed hopper, or
replace the powder in the hopper with
virgin powder.
Powder not suitable for tribo-charging Consult with your powder manufacturer.
4. Inadequate
powder flow
Flow-rate air pressure too low Increase the flow-rate air pressure.
Blockage in system Clean the pickup tube, pump, feed hose,
diffuser, and gun. Make sure the
powder is not damp. Check the air
dryer.

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Repair
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
Inner and Outer Charge Sleeve Replacement
To replace the charge sleeves, you will need the
Sinner charge sleeve kit
Souter charge sleeve
Disassembly
1. Clean the gun as described in Maintenance.
2. See Figure 4. Pull the diffuser (1) out of the gun body with a slight
twisting motion.
3. Pull the outer charge sleeve support (3) out of the gun body with a slight
twisting motion. The deflector (4) will pop out. Be careful not to lose it.
4. Slide the pattern adjuster retainer (2) away from the outer charge sleeve
O-ring (8). The retainer can remain on the outer charge sleeve support,
unless replacement is necessary.
5. Push, then pull the inner charge sleeve assembly (7) out of the outer
charge sleeve. The inlet distributor (5), guide (6), and outlet distributor
(10) are the only parts of the inner charge sleeve assembly that can be
replaced separately. To replace these parts unscrew the distributor from
the rest of the assembly.
NOTE: The inlet distributor and guide can only be installed on the tapered
end of the inner sleeve.
6. Push, then pull the outer charge sleeve (9) out of the gun body.
7. Remove the O-ring (8) from the outer charge sleeve. If it is undamaged,
it can be used on the new charge sleeve.

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5
6
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Figure 4 Inner and Outer Charge Sleeve Replacement
1. Diffuser
2. Pattern adjuster retainer
3. Outer charge sleeve support
4. Deflector
5. Inlet distributor
6. Guide
7. Inner charge sleeve assembly
8. O-ring (sleeve)
9. Outer charge sleeve
10. Outlet distributor
11. O-ring (body)
Assembly
1. See Figure 4. Install the O-ring (8) on the new outer charge sleeve.
Make sure the O-ring (11) in the gun body is undamaged. Replace the
O-ring if necessary.
2. Install the new outer charge sleeve into the gun body.
3. Install the new inner charge sleeve assembly into the outer charge
sleeve.
4. Slide the pattern adjuster retainer over the outer charge sleeve support.
Push the outer charge sleeve support over the outer charge sleeve and
into the body until it is seated.
5. Install the deflector on the end of the inner charge sleeve assembly.

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Outer Charge Sleeve Support and Pattern Adjust Sleeve Replacement
The outer charge sleeve support kit includes the support tube, a pattern
adjuster retainer, and O-rings. The pattern adjust sleeve must be
purchased separately. To remove and replace the pattern adjust sleeve,
perform the following steps:
1. See Figure 5. Pull the outer charge sleeve support (1) out of the gun
body with a slight twisting motion. The deflector (3) will pop out. Be
careful not to lose it.
2. Pull the pattern adjust sleeve (4) forward.
3. Slide the pattern adjuster retainer (2) off the outer charge sleeve
support.
4. Roll the black O-ring (5) onto the tube as shown.
5. Slide the pattern adjust sleeve down the tube.
6. Check the O-rings (5, 6) and replace them if they are worn or damaged
before installing a new pattern adjust sleeve.
13
5
4
6
2
Figure 5 Outer Charge Sleeve Support and Pattern Adjust Sleeve Replacement
1. Outer charge sleeve support
2. Pattern adjuster retainer
3. Deflector
4. Pattern adjust sleeve
5. O-ring (black)
6. O-ring (red)

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Handle, Trigger, and Cable Replacement
To replace the handle, trigger, or cable, you must disassemble the handle.
Kits are available to replace the handle or trigger. To replace the trigger
switch you must replace the cable.
Handle Disassembly
The handle assembly consists of two parts, the handle and the cover.
Threaded brass inserts, used to secure the cover, trigger, trigger switch,
ground wire, and hanger, are molded into the handle.
1. See Figure 6. Loosen the three captive screws (10) in the cover (11).
2. Separate the cover from the handle (8).
3. Remove the body (4) from the handle. Remove the nut (6) and ground
wire (5) from the set screw (7).
4. Remove the screw (2), ground wire (3), and hanger (1) from the handle.
5. Unscrew the two small screws (13), then remove the trigger switch (12)
and actuator (15) from the handle. If replacing the cable (9), remove the
screws, washers, and actuator from the trigger switch.
6. Unscrew the pivot (17), then remove it and the trigger (16). Remove the
screw (14) to replace the trigger spring.

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6
5
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1
13
12
15
17
16
14
7
18
2
3
Figure 6 Handle, Trigger, and Cable Replacement
1. Hanger
2. Screw
3. Ground wire (green)
4. Body
5. Ground wire (blue)
6. Nut
7. Set screw
8. Handle
9. Cable
10. Captive screws
11. Cover
12. Trigger switch
13. Screws and washers
14. Screw
15. Actuator
16. Trigger
17. Pivot
18. Holes
Assembly
1. Install the green ground wire on the handle with the screw.
2. Install the hanger on the body.
3. Secure the blue ground wire to the set screw with the nut.
4. Secure the actuator and trigger switch to the handle with the two screws
and washers (flat and lock).
5. Install the trigger on the handle with the pivot.
6. Install the body into the handle. Make sure the pin in the handle fits into
the hole (18) in the body.
7. Arrange the wires so they will not be pinched between the handle
halves. Make sure the cable molding fits properly into the bottom of the
handle.
8. Install the cover and tighten the captive screws.

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Parts
To order parts, call the Nordson Finishing Customer Support Center at (800)
433−9319 or contact your local Nordson representative.
Using the Illustrated Parts List
Numbers in the Item column correspond to numbers that identify parts in
illustrations following each parts list. The code NS (not shown) indicates
that a listed part is not illustrated. A dash (—) is used when the part number
applies to all parts in the illustration.
The number in the Part column is the Nordson Corporation part number. A
series of dashes in this column (- - - - - -) means the part cannot be ordered
separately.
The Description column gives the part name, as well as its dimensions and
other characteristics when appropriate. Indentions show the relationships
between assemblies, subassemblies, and parts.
SIf you order the assembly, items 1 and 2 will be included.
SIf you order item 1, item 2 will be included.
SIf 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 part
number is a bulk item ordered in quantities or if the quantity per assembly
depends on the product version or model.
Letters in the Note column refer to notes at the end of each parts list. Notes
contain important information about usage and ordering. Special attention
should be given to notes.
Item Part Description Quantity Note
— 0000000 Assembly 1
1 000000 SSubassembly 2 A
2 000000 SS Part 1

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Gun Parts
See Figure 7.
Item Part Description Quantity Note
— 1076394 GUN, manual, Tribomatic 500, 6 meter cable 1
1 302422 SHANGER, manual gun 1
2 304390 SKIT, handle 1 A
3 132334 SPIVOT, trigger 1
4 982370 SSCREW, pan head, M2 x 25 1
5 133783 SSPRING, trigger, return 1
6 125617 STRIGGER, manual gun, modular 1
7 982487 SSCREW, pan head, M4 x 5 1
8 984121 SNUT, hex, #10-24 1
9 1076395 SCABLE, T2, 6 meter 1
10 132336 SACTUATOR, switch 1
11 983510 SWASHER, flat, 0.094 x 0.188 x 0.025, brass 2
12 983113 SWASHER, lock, #2 2
13 1070246 SSCREW, pan head, #2-56 x 0.437 in. 2
14 173138 SDEFLECTOR, 19 mm, flat, VS2, w/O-ring 1
NS 940084 SS O-RING, silicone, 0.188 x 0.312 x 0.063 in. 1
15 304389 SKIT, outer charge sleeve support 1 A
16 302402 SSLEEVE, pattern adjuster 1
17 302407 SSLEEVE, outer charge 1
18 940175 SO-RING, silicone, 0.688 x 0.813 x 0.062 in. 1
19 304388 SKIT, inner charge sleeve 1 A
20 302413 SSCREW, set, #10-24 x 0.375 in. 1
21 941181 SO-RING, silicone, 0.875 x 1.063 x 0.094 in. 1
22 - - - - - - SBODY, handle interface 1
23 302410 SKIT, diffuser 1 A
NS 247006 SCLAMP, hose, 0.6730.795 in. 1
NS 900517 STUBING, poly, spiral-cut 2
NOTE A: Refer to the kit lists for included parts.
NS: Not Shown