Nordson Trilogy User manual

TrilogytManual
Electrostatic Air Spray/HVLP
Solventborne Spray Gun
Customer Product Manual
Part 1093591-02
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 1093591-02 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 2009. 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.
Loctite is a registered trademark of Loctite Corporation.
MagnaLube is a registered trademark of General Magnaplate Corporation.
Viton is a registered trademark of DuPont Performance Elastomers. L.L.C.
All other trademarks are the property of their respective owners.

Table of Contents i
Part 1093591-02
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Table of Contents
Safety 1-1..................................................
Introduction 1-1.............................................
Qualified Personnel 1-1......................................
Intended Use 1-1...........................................
Regulations and Approvals 1-1...............................
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.............................................
Spray Gun Features 2-2...................................
Spray Technology 2-2.....................................
Options 2-2..............................................
Coating Materials 2-2......................................
Theory of Operation 2-3.....................................
Trigger Lock 2-3..........................................
Electrostatic Charge 2-3...................................
Fluid Flow 2-3............................................
Air Flow 2-5..............................................
Specifications 2-5...........................................
Dimensions 2-5...........................................
Weight 2-5...............................................
Operating Pressures 2-5...................................
Electrostatics 2-6.........................................
Spray Gun Fitting Sizes 2-6................................
Optional Air Hoses 2-6.....................................
Approvals 2-6............................................
Installation 3-1.............................................
Preparation 3-1.............................................
Typical Air Spray and HVLP System 3-2........................
Air and Fluid Hose Connections 3-3............................
Air Hose Selection and Connection 3-3......................
Fluid Hose Selection and Connection 3-3.....................
Fluid Hose Connection 3-3...............................
Gun Cable Connection 3-4...................................
Securing Hoses and Cables 3-5...............................
Fluid Tip and Air Cap Installation 3-5..........................

Table of Contents
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Part 1093591-02 E2019 Nordson Corporation
Operation 4-1..............................................
Introduction 4-1.............................................
System Startup 4-2..........................................
Spray Adjustments 4-3......................................
Fluid Pressure and Flow Rate Adjustments 4-3...............
Spray Pattern and Atomization Adjustments 4-3..............
Fluid Tips and Air Caps 4-4.................................
Shutdown 4-5...............................................
Short-Term Shutdown 4-5..................................
Long-Term Shutdown 4-5..................................
Multi-Component Coatings 4-5..............................
Needle Travel Adjustment 4-6................................
HVLP Performance Testing 4-6................................
HVLP Compliance Test 4-6.................................
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 6-4...................
Electrostatic Troubleshooting 6-6..............................
Multiplier and Needle Continuity and Resistance Check 6-7.......
Gun Cable Continuity Check 6-8..............................
Repair 7-1.................................................
Tools/Supplies Required 7-2..................................
Air Cap, Fluid Tip, and Needle Replacement 7-3................
Trigger Lock Replacement 7-4................................
Repair Preparation 7-4......................................
Packing Cartridge Replacement 7-5...........................
Removing the Extension 7-5...............................
Removing the Packing Cartridge 7-6........................
Packing Cartridge Installation 7-7...........................
Needle Travel Adjustment 7-8..............................
Extension Installation 7-9..................................
Cable and Air Inlet Fitting Replacement 7-10....................
Handle Cover Removal 7-10................................
Cable and Fitting Replacement 7-10.........................
Cable and Handle Cover Installation 7-10.....................
Air Valve Repair 7-12.........................................
Horn Air Valve Repair 7-14....................................
Multiplier Replacement 7-14...................................
Multiplier Removal 7-14....................................
Fluid Tube Replacement 7-16.................................
Service Notes 7-18
...........................................

Table of Contents iii
Part 1093591-02
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Parts 8-1...................................................
Introduction 8-1.............................................
Spray Gun Parts 8-1.........................................
Repair Kits 8-4..............................................
Air Seal 8-4..............................................
Air Valve 8-4.............................................
Trigger Lock 8-4..........................................
Needle Kit 8-4............................................
Ferrule Kit 8-4............................................
Recommended Spare Parts 8-5...............................
Options 8-5.................................................
Air Caps and Fluid Tips 8-5................................
Adhesives, Sealants, and Lubricants 8-5.....................
Cable Extension 8-6......................................
Fluid and Air Hoses and Fittings 8-6.........................
HVLP Compliance Kit 8-6..................................

Table of Contents
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Part 1093591-02 E2019 Nordson Corporation

Safety 1-1
Part 1093591-02
E2019 Nordson Corporation
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
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.

Safety
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Part 1093591-02 E2019 Nordson Corporation
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 1093591-02 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 1093591-02
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.
Table 1-1 Safety Label
Symbol Description
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
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Part 1093591-02 E2019 Nordson Corporation

Description 2-1
Part 1093591-02
E2019 Nordson Corporation
Section 2
Description
Introduction
See Figure 2-1.
The Trilogy manual electrostatic air spray/HVLP solventborne spray gun is
designed for use with solventborne coating materials. It has an internal
user-replaceable voltage multiplier that generates the high voltage used to
electrostatically charge the coating materials as they are sprayed from the
gun. Electrostatic output voltage and air pressure are controlled by an
IPS-20 manual control unit.
The spray gun is non-circulating and can be used with heated and unheated
non-circulating spray systems. For systems that require circulation, a
circulation fitting can be coupled to the fluid inlet fitting. Refer to the Parts
section for ordering information.
HVLP and air spray systems use low-pressure fluid sources, such as
pressure pots, diaphragm pumps, or low-ratio piston pumps. They are
commonly used to apply low to medium viscosity fluids to products requiring
a high-quality finish.
2
1
4
5
3
8
7
6
Figure 2-1 Trilogy Air Spray/HVLP Manual Electrostatic Spray Gun
1. Fluid flow adjust knob
2. Trigger lock
3. Gun cable
4. Fluid fitting 3/8 in. NPSM
5. Air fitting 1/4 in. NPS
6. kV switch
7. Horn air adjust knob
8. kV LED

Description
2-2
Part 1093591-02 E2019 Nordson Corporation
Spray Gun Features
The Trilogy spray gun features:
Sadjustable horn air pressure and fluid flow rate
Slarge air passages for higher air energy
Suser-replaceable voltage multiplier
Sbellows-type packing cartridge
Spray Technology
The fluid tip and air cap you choose to use determines the spray gun
technology: air spray or HVLP.
HVLP technology creates a soft spray with high transfer efficiency,
reducing emissions of volatile organic compounds (VOCs). HVLP spray
guns use high volumes of very low pressure pattern control (horn) and
atomizing air (less than 0.69 bar (10 psi)). The high volume of pattern
control air provides sufficient energy to shape the pattern of sprayed fluids.
The low atomizing air pressure reduces fluid bounceback and overspray,
which improves transfer efficiency.
HVLP atomization is typically coarser than air spray when used with
high-viscosity fluids and high flow rates.
Air spray technology atomizes material at higher air pressures and lower
air flows than HVLP spray guns. Air spray guns produce a very fine,
atomized mist. This makes them useful for extremely fine finishing work.
Options
Options include a variety of fluid tips and air caps, air and fluid hoses,
fittings, and a cable extension. HVLP compliance kits are available for each
HVLP air cap.
Coating Materials
The spray gun is compatible with a wide variety of solventborne coating
materials including
Sgeneral solvent-based
Smetallics
Shigh-solids
Smulti-component
Sultra-violet coating
NOTE: The seals installed 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
Part 1093591-02
E2019 Nordson Corporation
Theory of Operation
See Figure 2-2.
Trigger Lock
The gun includes a trigger lock (11) to prevent accidental triggering of the
spray gun and possible injection injuries.
Electrostatic Charge
When the spray gun trigger is pulled, air flows through the control unit
airflow switch and gun. The airflow switch closes a circuit and allows the
gun control unit to delivers 0−21 Vdc through a cable (8) to the voltage
multiplier (3) housed in the extension (4) of the spray gun. The voltage
multiplier generates high voltage which creates a corona discharge around
the gun electrode (1) and an electrostatic field from the electrode to the
grounded parts. The voltage LED (5) at the back of the gun lights when the
voltage multiplier is turned on.
The kV switch (6) at the back of the gun turns the voltage multiplier off and
on at the gun. This allows the operator to turn off the high voltage and
eliminate the Faraday cage effect when coating parts with deep recesses.
Resistors within the multiplier limit the output current of the voltage multiplier
to safe levels. The high voltage electrostatically charges the coating
material as it is sprayed. The charged coating material is attracted to the
grounded parts.
Fluid Flow
Fluid enters the spray gun through a fluid supply hose (10) attached to the
extension and flows past the packing cartridge to the fluid tip (2). When the
trigger (12) is pulled it pulls the needle (15) off its seat in the fluid tip,
allowing fluid to flow out of the gun. The fluid control knob (13) controls how
far the needle is pulled off the seat, which determines fluid flow through the
fluid tip.
NOTE: If you are regulating fluid flow and pressure with an external fluid
regulator, the fluid control knob should be adjusted to allow full trigger travel
and fluid flow.
The packing cartridge (14) prevents fluid from flowing past it into the handle.
The fluid flow is dead-ended at the spray gun when the trigger is released.

Description
2-4
Part 1093591-02 E2019 Nordson Corporation
7
4
12
10
9
8
11
1
5
6
13
18
19
17
16
20
2
15 14
3
Figure 2-2 Spray Gun Components and Operation
1. Electrode
2. Fluid tip
3. Multiplier
4. Extension
5. Voltage LED
6. kV switch
7. Handle
8. Gun cable
9. Atomization and horn air inlet
10. Fluid tube
11. Trigger lock
12. Trigger
13. Fluid control knob
14. Packing cartridge
15. Needle
16. Heat sink
17. Horn air valve
18. Horn air adjust knob
19. Air cap
20. Air valve

Description 2-5
Part 1093591-02
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Air Flow
The atomization and horn air enter through the inlet fitting (9) in the spray
gun handle (7).
Pulling the trigger opens the air valve (20), allowing air to flow through the
atomization and horn air passages to the air cap. The air flow triggers an
pressure switch attached to the control unit, which turns on power to the
voltage multiplier in the spray gun.
Atomization air flows past the heat sink (16) and through the handle and
extension to the air cap when the spray gun is triggered. The atomization
air atomizes the coating material as it exits the nozzle. To control
atomization, adjust the air pressure regulator that supplies the control unit
and gun.
Horn air flows past the horn air valve (17) to the air cap (19) and shapes the
spray pattern. The horn air flow is controlled by adjusting the valve with the
adjust knob (18).
Specifications
Dimensions
Dimensions Metric (cm) English (in.)
Height 22.28 8.77
Length 30.48 12.00
Width 5.58 2.20
NOTE: The spray gun dimensions include the fluid and air fittings.
Weight
Weight Metric (g) English (oz)
Airspray/HVLP spray gun 887 31.3
NOTE: The spray gun weight includes the fluid and air fittings.
Operating Pressures
Operating Pressures Metric English
Maximum air input pressure 6.9 bar 100 psi
Maximum fluid input pressure 6.9 bar 100 psi
Maximum fluid temperature 82 _C180 _F
NOTE: Supply air must be particulate free (5 microns maximum) and oil
free. Use coalescing-type air filters.

Description
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Part 1093591-02 E2019 Nordson Corporation
Electrostatics
Maximum voltage: 93 kV
Maximum output rating current: 122 microamps
NOTE: Current draw greater than 50 μA may affect spray pattern, transfer
efficiency and finish. If the conductivity of your material causes excessive
current draw, changing to a longer hose may be necessary.
Refer to Fluid Hose Selection in the Installation section.
Spray Gun Fitting Sizes
Spray Gun Standard Fitting Sizes
Air fitting 1/4-in. NPS, Male
Fluid fitting 3/8-in. NPS, Male
Optional Air Hoses
Length ID Fittings
9.14, 15.24, 30.48 meter
(30, 50, 100 ft.)
9.25 mm
(3/8 in.)
1/4 in. NPS
female fittings
Approvals
This spray gun has met the requirements for FM approval.

Installation 3-1
Part 1093591-02
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.
Fluid tips, air caps, and fluid and air hoses are not shipped with the spray
gun. You must order them separately, based on your application. If you
order a HVLP air cap, order the appropriate compliance kit also. You will
need one compliance kit for each air cap size you use.
Compliance caps are used to verify compliance of non-electrostatic HVLP
systems. Electrostatic guns are by themselves compliant spray
technologies so it is not necessary to verify air cap compliance. Instead,
you may want to use a compliance kit to make sure the air cap pressure is
at optimum level.
Before installation,
Sremove the spray gun, brushes, and tool kit from the box.
Smake sure you have the appropriate fluid tip and air cap for your
application.
Smake sure you have air and fluid hoses of the correct length, ID, and
materials.
WARNING: Risk of fire and/or electrical shock if the spray gun and system
components are not properly grounded.
Smake sure the system is properly grounded.
NOTE: Inadequately grounded parts will adversely affect transfer efficiency
and coating quality.

Installation
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Part 1093591-02 E2019 Nordson Corporation
Typical Air Spray and HVLP System
Figure 3-1 shows the components of a typical air spray and HVLP system.
NOTE: Some components shown are optional. Make sure your system
contains self-relieving shutoff valves for both air and fluid supply.
1
2
3456 7 8
876
10
14
13
16
15
11
9
17
18
12
Figure 3-1 Typical Air Spray and HVLP System
1. Spray gun
2. Fluid filter
3. Fluid heater
4. Pump
5. Air lubricator
6. Air regulator
7. Air filter
8. Self-relieving shutoff valve
9. Fluid supply
10. Drain vavle
11. Siphon rod
12. Siphon screen
13. Air supply hose
14. Control unit
15. Gun cable
16. Air hose
17. Fluid hose
18. Fluid pressure regulator