Praxair SG-100 User manual

Revision H Issued: 12/11
Model SG-100
Plasma Spray Gun
Operator’s Manual
Manual Part Number: 05001760

EC Declaration of Conformity
We, Praxair Surface Technologies, 146 Pembroke Road, Concord, NH 03301
USA, declare under sole responsibility that the Model SG-100 Plasma Spray Gun
to which this declaration relates is in conformity with the relevant provisions of the
following standard(s) or other document(s):
Electromagnetic Compatibility Directive 2004/108/EC
EN 60974-10:2003:
CISPR 11:1997, 5.1.2, Table 2A
CISPR 11:1997, 5.2.2, Table 3
EN60974-10:2003:
EN 61000-4-2:1995/A1:1998/A2:2001
EN 61000-4-4:2004,
EN 61000-4-6 :1996/A1:2001
EN 61000-4-11:2004,
Machinery Directive(s) 2006/42/EC, EU Low Voltage Directive(s) 2006/95/EC
EN 60204-1:2006
We hereby declare that the equipment specified above conforms to the above
directive(s) and standard(s).
Signature:
Full Name: Stephen Ford
Position: Engineering Manager
Praxair Surface Technologies, Inc.
146 Pembroke Road
Concord, NH 03301
[phone] phone
[phone] fax

DISCLAIMERS
All information referred to and/or included in this manual is current as of the original issue date of
this manual. Praxair Surface Technologies, Inc. makes no warranty or representation with respect to
the accuracy of the information contained therein nor with respect to the suitability of the use of
such information outside Praxair Surface Technologies, neither does Praxair Surface Technologies
assume responsibility for any injury or damage which may result, directly or indirectly, from the
use of such information.
The information contained herein is offered for use by technically qualified personnel at their
discretion and risk without warranty of any kind. Praxair Surface Technologies is constantly
improving its products, and specifications are subject to change without notice.
This manual could include technical inaccuracies or typographical errors. Changes are made
periodically to the information herein; these changes will be incorporated in subsequent revisions of
the manual. Praxair Surface Technologies reserves the right to make improvements and/or changes
to the product(s) and/or programs described in this manual at any time and without notice.
Illustrations are meant to be representative of, but not exact duplicates of, existing equipment.
BUSINESS CONFIDENTIAL
THIS MANUAL CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION
OF PRAXAIR SURFACE TECHNOLOGIES. THIS INFORMATION IS PROVIDED IN
CONFIDENCE SOLELY FOR USE WITH OUR MODEL SG-100 PLASMA SPRAY GUN.
THIS MANUAL MAY NOT BE REPRODUCED IN ANY FORM OR ITS CONTENTS
DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
PRAXAIR SURFACE TECHNOLOGIES.
TRADEMARK INFORMATION
Praxair and the Flowing Airstream design are trademarks or registered trademarks of Praxair
Technology, Inc. in the United States and other countries.
TAFA and the TAFA Flame design are trademarks or registered trademarks of Praxair S.T.
Technology, Inc. in the United States and other countries.
Other trademarks used herein are trademarks or registered trademarks of their respective owners.
Praxair Surface Technologies, Inc.
Printed in the United States of America. Copyright © 2011 Praxair S.T. Technology, Inc.

Model SG-100 Plasma Spray Gun
Operator’s Manual
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Safety First Read This Before Using
Thermal Spray Equipment
WARNING
Read and understand operator’s manual before using this
machine. Failure to follow operating instructions could result in
injury or damage to equipment.
Thermal spraying is powerful technology. Do not use equipment
carelessly or without observing safe practices. Be safe!
Learn the recommended procedures and standards.
Failure to follow recommended procedures and standards
can result in severe injury to people and damage to equipment.
Who should use Thermal Spray Equipment?
Use the equipment only if you have been trained fully in safely using it.
Do not allow untrained persons to install, operate, or maintain the
equipment.
Understand what to do before you do it!
Make sure that you have read and understand the contents of this manual -
especially the safety guidelines and operating procedures - before
installing, operating, or maintaining this equipment. Contact a Factory
Representative if you do not fully understand any guidelines or
instructions.

Model SG-100 Plasma Spray Gun
Operator’s Manual
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Generic Thermal Spray Process
Sources of Information
To work safely with thermal spray equipment, become familiar with these
items:
This manual and related documentation, especially:
-Safe practices and safety guidelines described in section 1 and in
highlighted paragraphs throughout this guide
-Operating instructions (see section 4)
Technical bulletins included with or referred to in this manual. This
includes industry publications that contain standards that may apply to
your work. (See page vi of this guide for a list of industry
publications.)
Labels, tags, other instructions, and warnings that come with or are
attached to the equipment
Guidelines and practices your specific site has established as standard
About This Manual
This manual presents information about setting up, operating, maintaining,
and troubleshooting your equipment.

Model SG-100 Plasma Spray Gun
Operator’s Manual
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Conventions
Throughout this manual, certain words and symbols are used to draw your
attention to important information. These symbols and words have the
following meaning:
Praxair Surface
Technologies
RECOMMENDS
A procedure or setting that will produce optimum results
Information that can help to operate the equipment more effectively.
Refer to the manual before doing any maintenance.
Wear respirator.
Risk of eye injury. Eye protection required.
Wear opaque eye protection.
Wear protective clothing, gloves.
Wear hearing protection.
Pressure Relief
WARNING
This device is designed for use with Argon and/or Nitrogen gas.
The gases used with this device pose and asphyxiation hazard.
USE THIS DEVICE ONLY IN A WELL VENTILATED AREA.

Model SG-100 Plasma Spray Gun
Operator’s Manual
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WARNING
PERSONAL INJURY HAZARD:
Use caution when handling the powder feeder, feed lines and
fittings. There is a possibility of static electricity discharge from the
powder feed system which could result in significant discomfort or
injury.
HAZARD
Hazards that can result in minor or major damage to equipment,
bodily injury to people, and how to prevent such hazards.
EXPLOSION HAZARD
ELECTRIC SHOCK HAZARD
FIRE HAZARD
HIGH TEMPERATURE HAZARD
ELECTROMAGNETIC FIELDS HAZARD
LIGHT EMISSION HAZARD
People with Heart Pacemakers Not Allowed

Model SG-100 Plasma Spray Gun
Operator’s Manual
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Related Publications
Information that can help
OSHA (Occupational Safety and Health Administration) establishes
mandatory federal safety regulations. For information about the
regulations, refer to OSHA Standards, Code of Federal Regulations,
Title 29, Part 1910.
Handling compressed gas is among the safety hazards associated with
thermal spraying. ANSI/AWS Z49.1, Safety in Welding and Cutting
and the Williams-Steiger Occupational Safety and Health Act of 1970
(84 Stat. 1943) cover safe handling of compressed gases. More recently,
the Resource Conservation and Recovery Act (RCRA), dealing with the
disposal of toxic wastes, potentially affects the thermal spray industry.
Occupational Safety and Health Act Standards (29CFR 1910),
available from the Superintendent of Documents, U.S. Government
Printing Office.
Ventilation, Occupational Safety and Health Standard OSHA
1910.94, available from the Occupational Safety and Health
Administration.
Safety in Welding and Cutting, AWS/ANSI Z49.1, available from the
American Welding Society.
Environmental, Health, and Safety Guidelines, available from TSS an
affiliate society of ASM International (ASM TSS).
Requirements for Personal Eye and Face Protection, ANSI Z87.1-
2003, available from the American National Standards Institute.
Standard Practices for Respiratory Protection, ANSI Z88.2, available
from the American National Standards Institute.
Safety Requirements for Industrial Head Protection, ANSI Z89.1,
available from the American National Standards Institute.
National Electrical Code, NFPA 70-2011, available from the National
Fire Protection Association, updated annually.
Safe Handling of Compressed Gases, CGA Pamphlet P-1, available
from the Compressed Gas Association.

Model SG-100 Plasma Spray Gun
Operator’s Manual
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Oxygen, CGA Pamphlet G-4, available from the Compressed Gas
Association.
NFPA 50 Bulk Oxygen Systems at Consumer Sites, available from the
National Fire Protection Association.
NFPA 55 Compressed Gases and Cryogenic Fluids Code, available
from the National Fire Protection Association.
NFPA 30 Flammable and Combustible Liquids Code, available from
the National Fire Protection Association.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
ANSI/AWS F3.2, available from the American Welding Society.
Safety Release Device Standards - Cylinders for Compressed Gases,
CGA Pamphlet S1.1-1963 and 1965 and S1.2-1963, available from the
Compressed Gas Association.
Power and Process Piping Package, ANSI B31.1, available from the
American National Standards Institute.
Acetylene, CGA Pamphlet G-1, available from the Compressed Gas
Association.
NFPA 51Standard for the Design and Installation of Oxygen-Fuel Gas
Systems for Welding, Cutting, and Allied Processes, available from the
National Fire Protection Association.
NFPA 51B Standard for Fire Prevention During Welding, Cutting
and Other Hot Work, available from the National Fire Protection
Association.
ANSI/NFPA 58 Liquefied Petroleum Gas Code, available from the
National Fire Protection Association.
Industrial Ventilation: A Manual of Recommended Practice ACGIH
(25th Ed., 2004)
American National Standard for Hand Protection Selection Criteria,
105-2011, available from the International Safety Equipment Association.

Model SG-100 Plasma Spray Gun
Operator’s Manual
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Table of Contents
Read This Before Using Thermal Spray Equipment................................................................iii
Section 1 Safety Guidelines....................................................................................................1
1.1 Reminder: Safety First!..........................................................................................................1
1.2 General Guidelines.................................................................................................................2
1.3 Fire Protection and Prevention ..............................................................................................2
1.3.1 Keep Work Areas Clean ..........................................................................................2
1.3.2 High Temperatures...................................................................................................2
1.3.3 Hazardous Materials ................................................................................................3
1.4 Safe Operating Conditions .....................................................................................................3
1.4.1 Compressed Gas Cylinders......................................................................................3
1.4.2 Flow Meters.............................................................................................................4
1.4.3 Compressed Air .......................................................................................................5
1.4.4 Flame Spray and HVOF Equipment........................................................................5
1.4.5 Plasma and Arc Spray Equipment............................................................................6
1.4.6 Abrasive Blast Machine...........................................................................................7
1.4.7 Handling and Manipulating Equipment...................................................................7
1.5 Protecting Workers.................................................................................................................8
1.5.1 Eye Protection..........................................................................................................8
1.5.2 Respiratory Protection..............................................................................................9
1.5.3 Noise Protection.....................................................................................................10
1.5.3.1 Noise and Noise Level.........................................................................10
1.5.3.2 Noise Duration.....................................................................................11
1.5.3.3 Hearing Protection ...............................................................................12
1.5.4 Protective Clothing ................................................................................................14
1.5.5 Confined Spaces.....................................................................................................15
1.5.5.1 Rapid Emergency Exit .........................................................................15
1.5.5.2 Factors to Consider ..............................................................................15
1.6 Toxic Material......................................................................................................................18
1.6.1 Beryllium and Lead................................................................................................18
1.6.2 Cadmium................................................................................................................18
1.6.3 Cobalt, Chromium, and Tellurium.........................................................................18
1.6.4 Tin and Zinc...........................................................................................................19
1.6.5 Solvents..................................................................................................................19
1.6.6 Threshold Limit Values .........................................................................................19
1.7 Safety Standards...................................................................................................................20
Section 2 Equipment Description........................................................................................21
2.1 Plasma Spray Process Description .......................................................................................21
Figure 2-1 SG-100 Specifications........................................................................................21
Figure 2-2 SG-100 Gun Dimensions....................................................................................22
2.2 SG-100 Gun Description......................................................................................................22
2.3 Water Cooling Requirements...............................................................................................22
2.4 Optional Items......................................................................................................................24
A. Adapters ..........................................................................................................................24
B. Extension Conversions ....................................................................................................24
C. Y-Splitter.........................................................................................................................24