Nordson Trilogy AAA Reference guide

TrilogyrAir-Assisted Airless
Automatic Spray Guns
Customer Product Manual
Part 1601057-02
Issued 09/20
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 1601057-02 E2020 Nordson Corporation
Table of Contents
Safety 1.......................................
Qualified Personnel 1.........................
Intended Use 1..............................
Regulations and Approvals 1..................
Personal Safety 2............................
High-Pressure Fluids 2.....................
Fire Safety 3................................
Halogenated Hydrocarbon Solvent Hazards 4.
Action in the Event of a Malfunction 4...........
Disposal 4..................................
Description 5..................................
Specifications 5..............................
Installation 6..................................
Converting to Manual Control 7................
Operation 8...................................
Maintenance 9................................
Cleaning 9..................................
Lubrication 9................................
Troubleshooting 10.............................
Repair 12......................................
Nozzle and Air Cap Replacement 12.............
Needle Replacement 12.......................
Needle Seal Replacement 13...................
Piston Replacement 13........................
Seal Ring Replacement 13.....................
Parts 14.......................................
Nozzles 16.....................................
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 2012. 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
Trilogy, Nordson and the Nordson logo are registered trademarks of
Nordson Corporation.
All other trademarks are the property of their respective owners.

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TrilogyrAAA Automatic Spray Guns
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 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.

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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 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 Safety Data Sheets (SDS) 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.
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 SDS 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:

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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 him this card
STell him 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.
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.

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Fire Safety (contd)
SProvide adequate ventilation to prevent dangerous concentrations of
volatile particles or vapors. Refer to local codes or your material SDS
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 SDS 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.
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.

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Description
The Trilogy Air-Assisted Airless Automatic Spray Guns are compressed-air
operated automatic spray guns for the application of sprayable fluids at high
pressures. The gun is shipped configured for remote control of triggering,
atomizing air, and fan pattern air. The gun can be converted to manual
control of atomizing and fan pattern air if needed.
All wetted parts are stainless steel. The gun can be used in both circulating
and non-circulating systems.
Specifications
Item Specification
Weight 670 grams (1.47 lb)
Dimensions 150 x 75 x 90 mm (5.9 x 2.9 x 3.5 in.) L x W x H
Fittings Fluid: 1/2−20 JIC elbow (US), G 1/4 straight (EU)
Atomizing and Fan Pattern Air: 3/8 in. (US), 8 mm (EU) tube
Trigger Air: 1/4 in. (US), 8 mm (EU) tube
Maximum Fluid Pressure 250 bar (3625 psi)
Maximum Fluid
Temperature
60 _C (140 _F)
Typical Fluid Flow Rate 0.26 l/min with a 0.23 mm nozzle, 2 bar air pressure, 100 bar fluid pressure,
and viscosity of 45 sec in 4 mm DIN-Becher
Maximum Air Pressure 6.0 bar (85 psi)
Recommended
Atomizing Air Pressure
1.5−4.5 bar (21−64 psi)
Recommended Trigger
Air Pressure
4.5−6 bar (64−85 psi)
Air Consumption Round Pattern Flat Pattern
At 1.5 bar (21 psi): 6.4 m3/h (226 ft3/h) 4.8 m3/h (169 ft3/m)
At 2 bar (28 psi): 7.4 m3/h (261 ft3/h) 5.8 m3/h (204 ft3/h)
At 2.5 bar (36 psi): 8.8 m3/h (310 ft3/h 6.7 m3/h (236 ft3/h)
At 3 bar (42 psi): 10 m3/h (353 ft3/h) 7.9 m3/h (278 ft3/h)
Sound Pressure Level (A) at Round Pattern Flat Pattern
1.5 bar (21 psi): 74 dB/A73 dB/A
2 bar (28 psi): 76 dB/A74 dB/A
3 bar (42 psi): 77 dB/A80 dB/A
(A) Sound pressure level measurements and specifications are in accordance with Third regulation to
apparatus safety law DIN 45635 part 1/04.84.

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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.
NOTE: Use an air filter/separator to condition your air supply. Clean, dry
air enhances spray quality and extends the life of the spray gun.
1. See Figure 1. Using the 10-mm mounting hole (1), mount the spray gun
as desired. If using 1/2 in. mounting bars, use the10 mm to 1/2 in.
adapter included with the gun.
2. Connect 1/4 in. (US) or 8 mm (EU) trigger air tubing to the fitting marked
St.
NOTE: Trigger air should be controlled by a 2-position 3-port solenoid valve
with quick exhaust.
3. Connect 3/8 in. (US) or 8 mm (EU) air tubing to the F and R ports. The
F port is for Fan Pattern air; the R port is for atomizing air. These ports
allow the remote control of coating atomization and fan pattern shape.
WARNING: The pressure rating of the fluid hoses should exceed the
maximum fluid pressure of the system. Do not use hoses with a lower
pressure rating.
4. Connect the fluid delivery and return hoses to the 1/2 in. JIC elbows (3)
or G 1/4 straight fittings (2).
5. If the system will be dead-ended, remove the elbow from one fluid fitting
and install the cap nut and seal (4, 5) shipped with the gun.
NOTE: Before using your spray gun for production, flush the spray gun with
solvent or a waterborne cleaning solution to remove any oil and
contaminants left over from the manufacturing process.
1
6
7
2 3
4
St
FR
52
Figure 1 Trilogy AAA Automatic Spray Gun

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Converting to Manual Control
To convert the gun to manual control of atomizing and fan pattern air order
two optional regulators (29) listed in the spray gun parts list.
1. Replace the Fand Relbows and adapter fittings with the regulators.
2. Remove the plug from the Sp port on the bottom of the gun and install
one of the elbow fittings removed in Step 1 . Supply air for atomizing
and fan pattern to the Sp fitting.
St
FR
Sp
Remove Adapter Fittings Install Regulators
Figure 2 Converting to Manual Control

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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.
See Figures 1 and 2. Triggering of the spray gun is accomplished by
applying air to the St port. Spray pattern adjustments can be made as
follows:
Item Description/Adjustment
Port RAtomizing air: Increase for finer spray, decrease for coarser spray.
(Manual control: Turn regulator clockwise to increase, counterclockwise to decrease)
Port FFan pattern air: Increase for round pattern; decrease for flat pattern.
(Manual control: Turn regulator clockwise for a round pattern, counterclockwise for a flat
pattern)
Fan Pattern
Orientation
1. Relieve all pressure to the spray gun.
2. See Figure 1. Loosen the air cap retainer (6).
3. Rotate the air cap (7) to the desired position.
4. Tighten the retainer securely.
Air Cap Horns
Air Cap Horns
Figure 3 Fan Pattern Orientation