Nordson Tribomatic Magnum User manual

TribomaticrMagnum
Automatic Powder
Spray Gun
Customer Product Manual
Part 343 547A
NORDSON CORPORATION DAMHERST, OHIO DUSA

E2000 Nordson Corporation
All rights reserved
343 547A
Issued 8/00
Manual 37-37
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.
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Table of Contents i
E2000 Nordson Corporation
All rights reserved 343 547A
Issued 8/00
Manual 37-37
Table of Contents
1. 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 4.........................
Disposal 4.................................................
2. Description 5.................................................
Specifications 6............................................
3. Installation 7.................................................
Gun Ground Connection 9...................................
Pneumatic Connections 9...................................
4. Operation 10.................................................
Startup 11.................................................
Optimum Powder Flow Rate 11............................
Fluidizing Air Pressure 12.................................
Flow-Rate Air Pressure 12.................................
Atomizing Air Pressure 1 13...............................
Atomizing Air Pressure 2 13...............................
Shutdown 13...............................................
5. Maintenance 14...............................................
Daily 14...................................................
6. Troubleshooting 15............................................

Table of Contents
ii
E2000 Nordson Corporation
All rights reserved
343 547A
Issued 8/00
Manual 37-37
7. Parts 17.....................................................
Using the Illustrated Parts List 17.............................
Spray Gun 18..............................................
Spacer 19.................................................
Chargetube 20.............................................
Diffuser 21.................................................

Tribomatic Magnum Automatic Powder Spray Gun 1
E2000 Nordson Corporation
All rights reserved 343 547A
Issued 8/00
Manual 37-37
Tribomatic Magnum Automatic Powder Spray Gun
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.
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.
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
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.
1. Safety
Qualified Personnel
Intended Use
Regulations and Approvals

Tribomatic Magnum Automatic Powder Spray Gun
2
E2000 Nordson Corporation
All rights reserved
343 547A
Issued 8/00
Manual 37-37
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.
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.
Personal Safety
Fire Safety

Tribomatic Magnum Automatic Powder Spray Gun 3
E2000 Nordson Corporation
All rights reserved 343 547A
Issued 8/00
Manual 37-37
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.
All work conducted inside the spray booth or within 1 m (3 ft) of booth
openings is considered within a Class 2, Division 1 or 2 Hazardous
location and must comply with 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’s platform, hoppers, photoeye supports, and
metal 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 the 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-metal 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.
Grounding

Tribomatic Magnum Automatic Powder Spray Gun
4
E2000 Nordson Corporation
All rights reserved
343 547A
Issued 8/00
Manual 37-37
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.
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.
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.
Dispose of equipment and materials used in operation and servicing
according to local codes.
Grounding (contd)
Action in the Event of a
Malfunction
Disposal

Tribomatic Magnum Automatic Powder Spray Gun 5
E2000 Nordson Corporation
All rights reserved 343 547A
Issued 8/00
Manual 37-37
The Tribomatic Automatic Powder Spray Gun uses friction (the tribo
effect) to electrostatically charge powder coating particles as they are
forced through the gun by compressed air. The gun is used with a
Tribomatic Magnum control unit.
See Figure 1. The gun consists of a chargetube (4), diffuser (1), and a
spacer (5). The gun mount (3) is used to mount the gun to a reciprocator,
oscillator, or a fixed gun stand.
3737001A
2
3
4
5
1
Fig. 1 Tribomatic Magnum Automatic Powder Spray Gun
1. Diffuser
2. Ground Stud
3. Gun mount
4. Chargetube
5. Spacer
Flow-rate air pumps powder out of the feed hopper and forces it through
the feed hose into the diffuser. Diffuser air mixes with the powder and
increases its speed. The powder and air mixture then passes through a
group of spiral tubes inside the chargetube. The collision of the powder
particles with the walls of the tubes electrostatically charges both the
powder particles and the tubes’ inner surface.
2. Description

Tribomatic Magnum Automatic Powder Spray Gun
6
E2000 Nordson Corporation
All rights reserved
343 547A
Issued 8/00
Manual 37-37
The tubes are grounded through the gun body, ground wire, and the
control unit. The charge picked up by the tubes is displayed in
microampheres at the control unit. The display indicates how well the
powder is charging (the higher the number, the stronger the charge the
powder is receiving). The strength of the charge the powder receives will
vary depending on many factors, including the powder type and its speed
through the gun.
Refer to Table 1.
Table 1 Specifications
Powder Flow
Maximum 300 g/min (11 oz/min)*
Minimum 30 g/min (1 oz/min)*
Recommended 150 g/min (5 oz/min)
*These rates depend on the powder, pump
venturi, powder hose, and the length and
dimension of the hoses.
Pneumatic
Consumption
Maximum 700 l/min ( 24.7 cfm)
Normal 300 l/min (10.5 cfm)
Dimensions
Length 95 cm (37 in.)
Diameter 7.5 cm (3 in.)
Weight 2930 g (6.5 lbs)
Air Supply Quality
Air must be clean and dry.
Use a regenerative desiccant or a refrigerated
air dryer capable of producing a 3.4 _C
(38 _F) or lower dewpoint at 6.9 bar (100 psi).
Use a filter system with prefilters and
coalescent filters capable of removing oil,
water, and dirt in the submicron range.
2. Description (contd)
Specifications

Tribomatic Magnum Automatic Powder Spray Gun 7
E2000 Nordson Corporation
All rights reserved 343 547A
Issued 8/00
Manual 37-37
WARNING: Allow only qualified personnel to perform the
following tasks. Follow the safety instructions in this document
and all other related documentation.
NOTE: The gun mount should be installed with the hinged portion of the
clamp facing up to prevent the gun from falling when the clamp is
opened.
1. See Figure 1. Install the gun mount (3) on a vertical bar mount.
2. Install the desired sprayhead on the spacer (5) with a clockwise
twisting motion.
3. Place the gun in the gun mount and tighten the clamp.
4. See Figure 2. Attach the ground wire (7) to the ground stud (4).
Tighten the knob.
5. Install the diffuser (6) on the gun.
6. Connect atomizing air 1 tubing (2) onto the diffuser and the labeled
fitting on the rear panel of the control unit.
7. Connect atomizing air 2 tubing (5) onto the diffuser and the labeled
fitting on the rear panel of the control unit.
8. Connect the powder feed hose (1) onto the diffuser and the powder
pump.
9. Adjust the gun-to-workpiece distance and vertical position using the
gun holder as an adjustment point.
3. Installation

Tribomatic Magnum Automatic Powder Spray Gun
8
E2000 Nordson Corporation
All rights reserved
343 547A
Issued 8/00
Manual 37-37
3737002A
1
2
54
3
76
Fig. 2 Attaching the Tubing
1. Powder feed hose
2. Atomizing air 1 tubing
3. Control unit rear panel
4. Ground stud
5. Atomizing air 2 tubing
6. Diffuser
7. Ground wire
3. Installation (contd)

Tribomatic Magnum Automatic Powder Spray Gun 9
E2000 Nordson Corporation
All rights reserved 343 547A
Issued 8/00
Manual 37-37
WARNING: All electrically conductive equipment in the spray
area must be grounded. Ungrounded or poorly grounded
equipment can store an electrostatic charge which can give
personnel a severe shock or can arc and cause a fire or
explosion.
Connect the gun ground wire to the red GUN GROUND connector at the
rear panel of the control unit. Refer to the manual shipped with the
Magnum control unit for the location of the ground.
The control unit is shipped with 8-mm and 10-mm tubing connnectors
installed in the input and output ports.
If you want to use to use 0.3125-in. or 0.3750-in. tubing, remove the
connectors, wrap the threads with PTFE tape and reinstall the connectors
on the control unit’s input and output ports.
For further instructions, refer to the manual shipped with the Magnum
control unit.
Gun Ground Connection
Pneumatic Connections

Tribomatic Magnum Automatic Powder Spray Gun
10
E2000 Nordson Corporation
All rights reserved
343 547A
Issued 8/00
Manual 37-37
WARNING: Allow only qualified personnel to perform the
following tasks. Follow the safety instructions in this document
and all other related documentation.
WARNING: Use appropriate respiratory protection. Breathing
certain airborne dusts (including finishing powders) may be
hazardous to your health. For specific guidance, ask the
powder manufacturer for a Material Safety Data Sheet (MSDS).
WARNING: Make sure the gun is grounded before spraying
powder or cleaning the gun with compressed air. Without a
ground connection the gun will become electrostatically
charged. Personnel touching the gun could receive a shock.
WARNING: All electrically conductive equipment in the spray
area must be grounded. Ungrounded or poorly grounded
equipment can store an electrostatic charge which can give
personnel a severe shock or arc and cause a fire or explosion.
WARNING: This equipment can be dangerous unless it is used
in accordance with the rules laid down in this manual.
Each automatic gun is controlled by one gun control unit which houses
electrical controls, a digital display, and regulators and gauges for
flow-rate and diffuser air. Refer to the manual shipped with the Magnum
control unit for operation instructions.
4. Operation

Tribomatic Magnum Automatic Powder Spray Gun 11
E2000 Nordson Corporation
All rights reserved 343 547A
Issued 8/00
Manual 37-37
Before activating the control unit, make sure that the
SBooth exhaust fans are activated
SPowder recovery system is operating
SPowder in the feed hopper is thoroughly fluidized
NOTE: Refer to the appropriate component manuals for startup
procedures.
1. Turn the control unit power switch ON. The module LED will light.
2. If you switch S5 to Continuous, the powder LED will light. Atomizing
and flow-rate air begins to flow through the powder pump and the
gun.
3. Set the fluidizing (auxiliary) air pressure as recommended in the
manual shipped with the Magnum control unit.
NOTE: Typical fluidizing air pressure is 1 bar (14 psi). Wait
10−15 minutes for the powder in the feed hopper to adequately
fluidize before spraying.
4. Make sure that the flow-rate and atomizing air pressures are correct.
Flow-rate air 1.5 bar (21 psi)
Atomizing air 1 2.0 bar (29 psi)
Atomizing air 2 2.5 bar (36 psi)
5. See Figure 2. Make sure that the tubing is connected correctly to the
rear panel of the control unit.
Optimum Powder Flow Rate
NOTE: These settings may be different from one powder to another.
Set flow-rate and atomizing air to the lowest possible pressures that
provide
San acceptable spray pattern
Sthe desired powder coverage, film build, and finish coverage
Startup

Tribomatic Magnum Automatic Powder Spray Gun
12
E2000 Nordson Corporation
All rights reserved
343 547A
Issued 8/00
Manual 37-37
Fluidizing Air Pressure
Set the fluidizing air pressure as specified in the manual shipped with the
Magnum control unit.
When properly fluidized, small air bubbles rise gently and uniformly to the
surface of the powder, making the powder look like it is boiling. If
necessary, adjust the fluidizing air pressure. In this state, the powder is
similar to a liquid, enabling the powder pump to easily transport the
powder from the hopper to the spray gun.
Fluidizing Air Pressure Results
Too low Powder flows heavily and inconsistently
Too high Powder boils violently and flows
unevenly with possible air pockets in the
powder stream
Flow-Rate Air Pressure
See Figure 2. Flow-rate air transports a powder and air mixture from the
feed hopper through the powder feed hose (1) to the spray gun.
Increasing the flow-rate air pressure increases the amount of powder that
the gun sprays and may increase the thickness of the powder deposited
on the part.
Flow-Rate Air Pressure Results
Too low Powder sprays unevenly or produces an
inadequate film build
Too high Powder velocity increases, causing
excessive film build or overspray which
reduces transfer efficiency and wastes
powder
Excessive flow-rate air pressure
accelerates the build-up of impact-fused
powder in the gun or pump, or causes
premature wear of the gun and pump
parts in contact with the powder
Keep the flow-rate air pressure to a minimum. This will reduce
overspray, which lessens
Sthe amount of recovered and recycled powder
Swear on system components such as pumps, spray guns, and filters
Smaintenance costs

Tribomatic Magnum Automatic Powder Spray Gun 13
E2000 Nordson Corporation
All rights reserved 343 547A
Issued 8/00
Manual 37-37
Atomizing Air Pressure 1
See Figure 2. Atomizing air pressure 1 (2) is added to the powder and
air stream to increase the powder velocity in the diffuser and to break up
clumps of powder.
Atomizing Air Pressure 1 Results
Too low Powder flows heavily and inconsistently
Too high Powder velocity increases, causing
excessive overspray, impact-fusion, and
premature wear of the pump and gun
parts
Increasing the atomizing air pressure decreases the powder flow rate of
some pumps, requiring minor adjustments in the flow-rate air pressure
setting to maintain the same powder flow rate.
Atomizing Air Pressure 2
See Figure 2. Atomizing air pressure 2 (5) is added to the powder to
increase the powder velocity through the gun. The higher the flow rate,
the higher the charge and wear on gun parts.
Atomizing air pressure 2 Results
Too low Powder flows heavily and inconsistently
Too high Powder velocity increases, causing
excessive overspray, impact-fusion, and
premature wear of the pump and gun
parts
Increasing the atomizing air pressure decreases the powder flow rate of
some pumps, requiring minor adjustments in the flow-rate air pressure
setting to maintain the same powder flow rate.
1. Turn the control unit power switch OFF. The solenoid valve closes
and shuts off air to the pump and gun. If you are using auxiliary air,
turn the regulator counterclockwise until the gauge reads zero.
2. Perform the daily maintenance procedures described in Maintenance.
Shutdown

Tribomatic Magnum Automatic Powder Spray Gun
14
E2000 Nordson Corporation
All rights reserved
343 547A
Issued 8/00
Manual 37-37
WARNING: Allow only qualified personnel to perform the
following tasks. Follow the safety instructions in this document
and all other related documentation.
Dust and powder accumulating on electrostatic equipment can cause
malfunctions resulting in fire and shock hazards. The entire system
should be cleaned periodically, along with the surrounding area.
1. Make sure all conductive equipment in the spray area, including the
guns, are connected to a true earth ground. The resistance from part
to ground, through the hangers and conveyor, must not exceed one
megohm. For best results, the resistance should be less than 500 Ω.
2. Check the air supply filters and separators and the air dryer to make
sure they are operating properly.
WARNING: Never blow out the chargetube with the ground
wire disconnected. A potentially dangerous charge will build up
in the chargetube which can cause severe electrical shock.
CAUTION: Always blow out the feed hose in the direction of
powder flow (from pump to gun). Never blow out the feed hose
from the gun back into the pump.
3. Disconnect the air fittings from the diffuser.
4. Disconnect the powder feed hose from the pump.
5. Blow out the powder feed hose, diffuser, and pump.
6. Disassemble and clean the pump and diffuser. Replace worn parts.
7. Reassemble the pump and diffuser.
8. Reattach the powder feed hose and air fittings.
5. Maintenance
Daily

Tribomatic Magnum Automatic Powder Spray Gun 15
E2000 Nordson Corporation
All rights reserved 343 547A
Issued 8/00
Manual 37-37
WARNING: Allow only qualified personnel to perform the
following tasks. Follow the safety instructions in this document
and all other related documentation.
This section contains troubleshooting procedures. 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 air supply to control unit Check the air supply to the system.
Flow-rate air pressure too low Increase the flow-rate air pressure.
Blockage in system 1. Disconnect the powder feed hose at
the pump. Blow out the hose with
compressed air.
2. Disassemble the pump and diffuser.
Clean them if necessary.
3. Check the powder supply in the
hopper for dampness. Replace the
powder supply if necessary.
4. Check the air dryer and filters.
Control unit solenoid valve
malfunction
Disconnect the air tubing from the
control unit. Turn the switch to
Continuous. If you do not feel air at the
control unit output when the gun is
triggered
1. Remove the cover of the control unit.
NOTE: The orange test button is
located on the right side of the solenoid,
as seen from the front of the unit.
2. Press the orange test button on the
solenoid.
3. Replace the valve if the valve does
not open when you press the test
button.
Continued on next page
6. Troubleshooting

Tribomatic Magnum Automatic Powder Spray Gun
16
E2000 Nordson Corporation
All rights reserved
343 547A
Issued 8/00
Manual 37-37
Problem Corrective ActionPossible Cause
2. Powder puffing from
gun
Powder pump throat worn out Change the powder pump throat.
Diffuser filter clogged Disassemble the diffuser and clean it.
Powder feed hose too long Shorten the hose.
Incorrect ratio of diffuser-to-flow-rate
air
Adjust the diffuser-to-flow-rate air
pressure ratio. Refer to Operation for
more information.
3. Poor powder charging
(no electrostatic wrap or
adhesion)
Flow-rate air pressure too high in
relation to diffuser air; powder velocity
prevents efficient charging
Reduce the flow-rate air pressure while
maintaining diffuser-to-flow-rate air
pressure ratio.
Powder not suitable for tribo charging Consult with the powder manufacturer.
Workpiece not properly grounded Check the conveyor rollers and hangers
for coating build-up that could affect the
ground. Resistance between the
workpiece and the earth ground should
not exceed 1 MΩ.
4. Inadequate powder flow Wet powder causing blockage in
system
1. Check the powder in the feed hopper
for dampness.
2. Check the air dryer and filters for
proper operation.
3. Clean the system components and
feed tubing.
Refer to Operation for more information.
Poor fluidization of powder Increase or decrease the fluidizing air
pressure. Allow the powder enough
time to fluidize properly before beginning
spray operations. Refer to Operation for
more information.
Incorrect ratio of diffuser-to-flow-rate
air
Adjust diffuser and flow-rate air pressure
settings. Refer to Operation for more
information.