Sulzer 16E User manual

© Sulzer Metco June 2009
16E / 16E-H / 16E-P Spray Gun
Combustion Wire Spraying
Product Manual
MAN 96150 EN 01

Sulzer Metco US, Inc.
1101 Prospect Avenue
Westbury, NY 11590
[phone]
[phone]
www.sulzermetco.com

16E / 16E-H / 16E-P Spray Gun
3
MAN 96150 EN 01
Intended Use
The 16E / 16E-H / 16E-P Spray Gun is a hand-held combustion ther-
mal spray gun for applying flame spray coatings using metalizing wire.
It is compatible with all commonly available combustion gas fuels
including acetylene, hydrogen, propane, natural gas, and MAPP/MPS.
The standard 16E is intended for most wires and gas fuels. The 16E-H
is intended for feeding softer wires at a higher speeds. The 16E-P is
specifically intended for use with propane.
See “Technical Data” on page 15 for detailed specifications.
Information About this Manual
The information in this manual is intended to ensure safe and optimal
operation of the 16E / 16E-H / 16E-P Spray Gun.
Keep this manual near your system.
Additional Documents
• 16E / 16E-H / 16E-P Spray Gun Parts List, PL 96151
• 16E / 16E-H / 16E-P Spray Gun Spray Parameters, PAR 96447
Copyright Restrictions
The reproduction, duplication or distribution of this manual, in whole or
in part, by any means, without prior written permission from Sulzer
Metco, is strictly prohibited.
Designation Characteristics
16E
16E-H
16E-P
Standard wire gun
High-speed wire gun
Propane wire gun
Spray Process Combustion wire
Compatibility:
Spray Controllers •3AF
•3GF
Material Feeder •2W
DANGER
Do not use the 16E /
16E-H / 16E-P Spray
Gun for any application
or purpose other than
that described in this
manual. Improper use
or application can result
inequipmentdamageor
personal injury.

16E / 16E-H / 16E-P Spray Gun
4MAN 96150 EN 01
Intended Audience
All personnel who work with the 16E / 16E-H / 16E-P Spray Gun shall
be familiar with the material in this manual. The specific topics of inter-
est are outlined in the table below.
Read the relevant chapters, especially chapter 1 Safety, before work-
ing with the 16E / 16E-H / 16E-P Spray Gun.
Sulzer Metco reserves the right to make improvements to the 16E /
16E-H / 16E-P Spray Gun without prior notice.
Chapter Intended Audience
1 Safety Everyone working with the spray gun
2 Product Description Everyone working with the spray gun
3 Installation Installation Engineers
4 Operation Everyone working with the spray gun
5 Troubleshooting Maintenance Engineers
6 Maintenance Maintenance Engineers

16E / 16E-H / 16E-P Spray Gun
5
MAN 96150 EN 01
Table of Contents
1 Safety
1.1 Safety Symbols..................................................................................................7
1.2 Authorized Use..................................................................................................9
1.3 General Safety Regulations...............................................................................9
1.4 Specific Safety Regulations...............................................................................9
2 Product Description
2.1 Technical Data.................................................................................................15
2.2 Component Descriptions ................................................................................16
2.2.1 Gas Head Assembly........................................................................................17
2.2.2 Front End.........................................................................................................17
2.2.3 Turbine and Speed Control .............................................................................18
2.2.4 Countershaft and Bearing Assembly...............................................................18
2.2.5 Wire Grip Mechanism and Drive Roll Carrier ..................................................19
2.2.6 Handle and Wire Feed Control........................................................................19
2.2.7 Rear Wire Guide and Snubber........................................................................19
2.3 Principles of Operation ...................................................................................20
2.3.1 Mechanical Operation......................................................................................20
2.3.2 Combustion .....................................................................................................20
2.3.3 Wire Feeding...................................................................................................21
2.4 Spray Gun Options..........................................................................................22
2.4.1 3XT Spray Gun Extensions ............................................................................22
2.4.2 14EWGM Manual Wire Grip Mechanism ........................................................22
2.5 Auxiliary Equipment.........................................................................................23
2.6 Hardware Selection.........................................................................................26
2.6.1 Front End Hardware .......................................................................................26
2.6.2 Wire Guides, Drive Rolls and Drive Gears .....................................................29
3 Installation
3.1 Exhaust System...............................................................................................30
3.2 Wire Control Unit.............................................................................................30
3.3 Connection ......................................................................................................31
4 Operation
4.1 Operating Controls .........................................................................................33
4.2 Operating Procedures .....................................................................................35
4.2.1 Setup...............................................................................................................35
4.2.2 Lighting............................................................................................................36
4.2.3 Spraying ..........................................................................................................37
4.2.4 Shutdown ........................................................................................................37
5 Troubleshooting
5.1 Avoiding Trouble..............................................................................................38
5.2 Difficult Lighting...............................................................................................38
5.3 Flashback / Backfire........................................................................................39

16E / 16E-H / 16E-P Spray Gun
6MAN 96150 EN 01
5.4 Sticking Wire....................................................................................................39
5.5 Lighting Flow Check........................................................................................40
6 Maintenance
6.1 General Gun Care...........................................................................................41
6.2 Siphon Plug.....................................................................................................41
6.3 Nozzles............................................................................................................41
6.4 Gas Head Valve ..............................................................................................42
6.5 Countershaft / Bearing Lubrication..................................................................42
6.6 Hoses ..............................................................................................................43
6.7 Scheduled Maintenance..................................................................................44
6.8 Replacing Common Parts................................................................................45
6.8.1 Front End Hardware .......................................................................................45
6.8.2 Drive Rolls and Gears ....................................................................................47
6.8.3 Rear Wire Guide and Snubber .......................................................................49
6.9 Disassembly....................................................................................................50
6.9.1 Wire Grip Mechanism......................................................................................50
6.9.2 Gas Head Assembly........................................................................................51
6.9.3 Handle and Wire Feed Valve...........................................................................53
6.9.4 Speed Control and Turbine .............................................................................54
6.9.5 Countershaft, Drive Shaft and Bearings..........................................................56
6.9.6 Central Housing...............................................................................................58
6.10 Assembly.......................................................................................................59
6.10.1 Countershaft, Drive Shaft and Bearings........................................................59
6.10.2 Speed Control and Turbine ...........................................................................61
6.10.3 Handle and Wire Feed Valve.........................................................................64
6.10.4 Gas Head Assembly......................................................................................65
6.10.5 Wire Grip Mechanism....................................................................................68
Index .............................................................................................................. 69

16E / 16E-H / 16E-P Spray Gun
7
MAN 96150 EN 01
1 Safety
This chapter contains important safety information. Please read it prior
to working with the spray process. Observe all safety regulations.
1.1 Safety Symbols
The following safety symbols may be found in Sulzer Metco documen-
tation, such as technical manuals and product labeling, to alert the
user to the presence of important operating instructions, safety consid-
erations and special instructions. Whenever these symbols are
encountered, the user should read, understand and proceed in accor-
dance with the definition provided below.
General Information and Warnings
INFO
Presentation of general, but important information
which must be read and understood prior to proceed-
ing.
CAUTION
General hazard warning which can result in minor
personal injury or minor damage to machinery.
WARNING
Warning of hazard which can result in severe per-
sonal injury or severe damage to machinery.
DANGER
Danger! Failure to comply can result in severe per-
sonal injuries or death.
Mandatory Requirements
Mandatory requirement not covered by other sym-
bols.
i

16E / 16E-H / 16E-P Spray Gun
8MAN 96150 EN 01
Additional Symbols
Personal Protection
Sound attenuating ear protection must
be worn. Hand protection must be worn.
Respiratory protection must be worn. Face protection (welding gear) must be
worn.
Protective clothing must be worn. Eye protection must be worn.
Head protection must be worn. Protective footgear must be worn.
Keep hands, hair, clothing and tools
away from moving parts.
Hazardous Materials and Conditions
Explosion hazard, explosive material
present. Strong electromagnetic fields present.
Flammable material or presence of
high temperatures. Poisonous substance present
High voltage or risk of electric shock
present. High pressure warning.
Ultraviolet, infra-red or other damag-
ing light radiation present. Warning of laser present.
Noise hazard present. Do not stack warning.
Heavy weight present above. Electrical ground is not present.

16E / 16E-H / 16E-P Spray Gun
9
MAN 96150 EN 01
1.2 Authorized Use
This system is intended for the sole use of thermal coating of work-
pieces in atmosphere. The combustion and HVOF spray systems are
designed and constructed in accordance with generally acknowledged
safety regulations and codes. The combustion and HVOF spray guns
must be used only for depositing thermal spray coatings following all
guidelines specified herein, other supporting equipment manuals, and
all applicable regulations and codes. Failure to do so may result in
hazardous or unsafe conditions.
1.3 General Safety Regulations
Use of Sulzer Metco original spare parts is strongly recommended.
Use of non-OEM parts may void Sulzer Metco's warranty and result in
reduced performance of the equipment.
It is recommended that all personnel connected with thermal spraying
become familiar with the safety practices outlined in this document as
well as the established standards and regulations which have been set
by local, state and federal health officials (e.g., OSHA). All regulations
should be thoroughly read and understood to ensure proper compli-
ance.
There are several basic precautions for thermal spraying which should
always be observed. These include: good housekeeping, proper mate-
rial/gas storage and handling practices, use and maintenance of
equipment, operator training, sufficient exhausting of gases and fumes
and personal protective equipment (clothing, ear, eyes and breathing
(respirator) protection).
All personnel responsible for the safe use of this equipment must read
and understand this instruction manual.
In addition, the operator of this equipment must receive personal
instructions in its use. A thorough understanding of the operation,
maintenance, and safety requirements of this equipment is required.
1.4 Specific Safety Regulations
Eye Protection
The combustion spray gun generates electromagnetic radiation in the
form of visible light, infrared (radiant heat), and ultraviolet radiation.
These types of radiation are hazardous and can cause burns or blind-
ness in unprotected eyes.
WARNING
Do not use the 16E /
16E-H / 16E-P Spray
Gun for any application
or purpose other than
that described in this
manual. Improper use
or application can result
inequipmentdamageor
personal injury.
DANGER
Wearsuitableprotective
goggles.

16E / 16E-H / 16E-P Spray Gun
10 MAN 96150 EN 01
Ear Protection
The noise emission of greater than 85 dB caused by the spray gun
can damage hearing. Personal protective equipment in accordance
with a hearing conservation program is necessary. The HVOF spray
process can produce noise levels as high as 136 dB.
Ventilation and Exhaust
All thermal spray processes produce fumes and dust particles from the
materials being sprayed. To avoid the effects of dust and fumes gener-
ated by spraying, a suitable spray booth and sufficient exhaust system
are required. Proper installation, operation and maintenance are
important for system performance and maintaining a safe working
environment. For additional safety, dust collectors should be provided
with blow-out or relief panels in case of explosion. All local, state, and
national fire codes must be complied with when determining the loca-
tion of the exhaust system. The exhaust duct of the ventilation system
should be vented to the outside of the building.
The combustion and HVOF spray processes generate carbon dioxide,
carbon monoxide, NOx, dust, and fumes that can damage the respira-
tory system or cause death. An adequate exhaust and ventilation sys-
tem is required. A minimum air velocity of 90 m/min (300 ft/min) is
recommended in the areas adjacent to the spray gun and the object
being coated.
In addition to proper booth ventilation, appropriate personal respiratory
equipment must always be used when the operator is near the spray
process. An industrial hygienist should be consulted for recommenda-
tions on type and fit. Consult the Material Safety Data Sheet (MSDS)
for the products being sprayed for specific information regarding
chemical composition of the powder and Permissible Exposure Limits
(PEL).
Personal Protection
Protect exposed skin from the dust, fumes, and heat, generated by the
combustion and HVOF spray process.
WARNING
Noise emissions!
Wear ear protection!
DANGER
Respiratory protection
must be worn.
WARNING
Hazards generated by
the spray process!
Wear personal protec-
tive clothing.

16E / 16E-H / 16E-P Spray Gun
11
MAN 96150 EN 01
Hazardous Materials
OSHA and groups such as the American Conference of Government
Industrial Hygienists (ACGIH) and other government agencies have
developed extensive lists of hazardous materials and have set work-
place exposure limits. Inasmuch as standards change and new infor-
mation becomes available from time to time, it is strongly
recommended that the information contained in the Materials Safety
Data Sheet (MSDS) be consulted for the latest, up to date information.
There is also a considerable body of European standards that apply to
the spraying of powders.
Electrical Power
All electrical installations must be made in accordance with local and
national code requirements. All electrically powered equipment must
always be properly grounded. For additional information concerning
electrical installations refer to the National Electric Code (NFPA 70), or
EN 60204-1, or applicable local electrical code.
Heat
The spray stream can heat up and ignite objects in the vicinity such as
the walls of the sound proof cabin, or cables and hoses. Never aim the
spray stream at people or objects other than the workpiece to be
coated.
WARNING
High current and volt-
age!
DANGER
High temperatures!
Never aim the spray
gun at people or flam-
mable objects!

16E / 16E-H / 16E-P Spray Gun
12 MAN 96150 EN 01
Compressed Gases
Local, state and federal regulations relative to in-building use and stor-
age of gas cylinders should always be observed. The improper stor-
age, handling or use of gas cylinders can result in a serious safety
hazard. For additional information refer to NFPA 50, 50A, 51, 54, and
55 or other applicable local codes.
Oil or grease should never come into contact, or be used on, equip-
ment which carries oxygen gas. Only approved lubricants should be
used in these cases.
The manifolding of more than two gas tanks may be required to permit
higher gas flows and longer spray times. Only approved pressure
adjusting regulators should be used with each gas, and should never
be over tightened or forced to make a connection. Gas regulator
adjusting screws should be fully released prior to opening cylinder
valves. Cylinder valves should be opened slowly to prevent surges
that can damage other related equipment. When opening a gas cylin-
der, stand to the side of the pressure-reducing regulator, never in front
of it.
It is dangerous and not recommended to use acetylene gas above
1.03 bar (15 psig). Consult the local country regulations for maximum
allowable acetylene pressures.
The following guidelines should be followed when handling gas tanks:
1 Never drop tanks or knock tanks into one another. Some gases are
unstable (e.g., acetylene) even when in the tanks.
2 Gas tanks should always be secured to a wall or other supporting
fixture with chains or similar restraints even when the tanks are not
in use as they can easily tip over.
3 Only transport tanks in proper carriers. Gas carts are designed to
move tanks around, dollies are NOT. Do not attempt to carry or
drag tanks
4 Never leave tanks in direct sunlight or extreme heat. Heat will
cause the tank pressure to increase dramatically resulting in an
unsafe situation.
5 Never smoke around tanks. Although no leak may be apparent,
some gas could be leaking and may ignite.
6 Tanks should always remain upright. They are designed to be
operated and transported in this position. If a tank is found lying on
its side, carefully return the tank to its upright position. Allow the
tank to remain upright for at least 30 minutes before attempting to
use it.
DANGER
Combustible gases
present under pressure.

16E / 16E-H / 16E-P Spray Gun
13
MAN 96150 EN 01
7 If a tank has been stored outside in a cold environment, allow the
tank to warm up at least one hour prior to use. A liquid tank (e.g.,
propylene) will require up to 4 hours to reach room temperature.
8 The caps on the gas tanks should be on at all times when the tank
is not in use. The cap is used to protect the weakest part of the
tank; that being the tank head.
9 Follow local guidelines and recommendations from the gas sup-
plier for the allowable location of combustible gas tanks storage.
Gas Hoses and Piping
The gas supply installation must be carried out by qualified personnel
and must comply with the regulatory requirements applicable to the
location of the spray cell set-up.
Where large amounts of gas are required, the gas can be supplied
from a tank or several manifolded gas tanks and piped into the spray
booth. Gas piping should be constructed from stainless steel or other
similar solid metal material. It is recommended that pipe connections
should be welded or brazed. Gas piping should when possible, be laid
above ground and on the outside of the building. Piping should not be
laid in enclosed areas where gas leaks can accumulate, such as
above ceiling tiles or behind walls. The piping installation must be
checked for leaks and pressure tightness before putting it into service.
The piping installation should be routinely checked for leaks when in
service.
Gas hose must be protected from mechanical damage. Gas hoses
should be routinely checked for loose connections, damage, and
leaks. Old gas hoses that are dry or cracked should never be used.
Hose connections should never be over tightened for this will cause
the hose stem to collapse and restrict gas flow.
Flame spray guns or torches or any other object should never be hung
on cylinder valves or regulators. This practice may result in a fire or
explosion.
When spray work has been completed or the equipment is shut down
(e.g., overnight, over a weekend), the gas supply should be turned off
and all gases should be drained from the hoses and regulator adjust-
ing screws backed out.
DANGER
Combustible gases
present under pressure.

16E / 16E-H / 16E-P Spray Gun
14 MAN 96150 EN 01
2 Product Description
The 16E / 16E-H / 16E-P Spray Gun is a hand-held, wire-fed, combus-
tion thermal spray gun. The spray gun is capable of using all com-
monly available combustion fuel gases, with oxygen to produce flame
sprayed coatings from Sulzer Metco metallizing wires. The spray gun
is intended mainly for hand-held operation. A tool post on the front of
the spray gun provides for machine or tool mounting.
There are three versions of the spray gun:
16E (Standard)
• 3.2 mm (1/8”) and 2.3 mm (11 Ga.) wire
• Optional hardware available for wire size ranging from 4.8 mm (3/
16”) to 1.45 mm (15 Ga.)
• Standard fuel gas = acetylene
• Other fuel gas = propane (natural gas, MPS)
16E-H (High-Speed)
• 3.2 mm (1/8”) and 4.8 mm (3/16”) soft wire (such as babbitt, tin,
zinc)
• Non load air cap
• Stepped down drive rolls
• High speed gear
16E-P (Propane)
• 3.2 mm (1/8”) and 4.8 mm (3/16”) wire
• Standard fuel gas = propane
16e_overview

16E / 16E-H / 16E-P Spray Gun
15
MAN 96150 EN 01
2.1 Technical Data
16E / 16E-H / 16E-P Spray Gun
Feature / Requirement SI Units US Units
Weight 2.83 kg 6.25 lb
Wire Feed Rate:
16E / 16E-P 0.6 – 4.6 m/min 2 ft/min – 15.1 ft/min
16E-H 1.4 – 11.7 m/min 4.5 ft/min – 38.5 ft/min
Spray Distance 130 – 205 mm 5” – 8”
Compressed Air Requirements
(Dried, Filtered, Oil-Free) 0.85 m3/min at 4.5 bar 30 CFM at 70 PSI
Process Gases:
Oxygen 3.45 bar at 85.4 NLPM 50 PSI at 195 SCFH)
Acetylene 1.03 bar at 21.9 NLPM 15 PSI at 50 SCFH
Propane 3.45 bar at 18.4 NLPM 50 PSI at 42 SCFH
MAPP (MPS) 3.45 bar at 17.5 NLPM 50 PSI at 40 SCFH
Hydrogen 1.72 bar at 92.0 NLPM 25 PSI at 210 SCFH)
Wire Sizes:1
1. All wire sizes cannot necessarily be used with all gases. See
“Hardware Selection” on page 26.
4.76 mm2
2. Wire sizes are listed in SI units for reference only. Wires for the
16E / 16E-H / 16E-P Spray Gun are supplied in standard US units
or average wire gauge (AWG).
3/16 in
3.97 mm 5/32 in
3.18 mm 1/8 in
3.06 mm 11 gauge
1.83 – 0.88 mm 15 – 20 gauge
16e_techdata
267mm
(10.5”) 159 mm (6.25”)
241 mm
(9.5”)

16E / 16E-H / 16E-P Spray Gun
16 MAN 96150 EN 01
2.2 Component Descriptions
16e_subassy
Drive Roll Carrier
Wire Grip Mechanism
Rear Wire Guide
& Snubber
Turbine &
Speed Control
Countershaft & Bearing Assembly
Gas Head Assembly with
Safety Handle & Valve Return
Front End
Handle with
Wire Feed Control
Central Housing
Air
O2
Fuel

16E / 16E-H / 16E-P Spray Gun
17
MAN 96150 EN 01
2.2.1 Gas Head Assembly
Supply hoses for air, oxygen and fuel gas connect to the hose block on
the bottom of the gas head assembly. The gas head valve has three
positions:
•Closed / Forward - All gases to the spray gun are shut off.
•Lighting / 45º - A detent in the valve handle indicates the exact
position. In the lighting position, the valve allows only oxygen and
fuel gas to flow to the nozzle. Air flow remains closed.
•Run / Vertical - Fuel gas and oxygen are set to the optimum levels
to sustain combustion and air is supplied to the front end and wire
drive components.
The gas head assembly features a safety handle and valve return
spring. When the safety handle is released, the valve return will
quickly close the gas head valve, extinguish the flame and stop the
wire from feeding. The safety handle shall not be overridden or
defeated.
The gas head assembly contains the spray gun front end hardware.
2.2.2 Front End
The front end hardware includes the front wire guide, siphon plug,
nozzle, nozzle nut, air cap and air cap body. Wire is fed through the
center of these parts.
The front wire guide, siphon plug, nozzle and air cap are determined
by the spraying application. (See “Hardware Selection” on page 26.)
WARNING
DANGER
DO NOT attempt to
override or defeat the
safety handle. Doing so
may result in personal
injury and equipment
damage. Local regula-
tions may require the
use of this safety fea-
ture.
Nozzle
16e_front_end
Front
Wire
Guide Siphon
Plug Nozzle
Nut
Air Cap Air Cap
Body

16E / 16E-H / 16E-P Spray Gun
18 MAN 96150 EN 01
2.2.3 Turbine and Speed Control
The turbine is air-driven and spins at a highrate of speed whenever air
flow is present (i.e., gas head valve is in the run position). Turning the
control ring decreases or increases pressure on the brake plate which
allows the turbine to spin faster or slower, thus adjusting the wire feed
rate.
2.2.4 Countershaft and Bearing Assembly
The following illustration shows the mechanical relationship between
the countershaft, drive shaft, turbine shaft and drive roll gears.
The turbine shaft meshes with the countershaft gear. This results in a
reduction in turn ratio from the turbine shaft to the countershaft. The
countershaft meshes with the drive shaft gear, resulting in a further
reduction in turn ratio to the drive shaft and the lower drive roll and
gear. The upper drive gear engages the lower drive gear only when
wire is being fed. When the upper and lower drive gears engage, the
upper and lower drive rollers grip and feed the wire.
Although the air turbine is light-weight and spins at very high speed
(up to 30,000 RPM), the gear reduction results in a much lower speed
and a much higher torque at the drive shaft. The reduction ratio
through the shafts and gears is not important, except to note that the
16E-H (high-speed) gun has a different turbine shaft and countershaft
gear for higher range of feed rate. Additionally, the upper and lower
drive rolls and gears can be changed to accommodate different
gauges of wires. (See “Hardware Selection” on page 26.)
The countershaft and bearing covers are gasket-sealed to the central
housing and contain Gearlube oil. The oil is circulated through an oil
pump by the motion of the countershaft and drive shaft gear.
Upper Drive Roll / Gear
Lower Drive Roll / Gear
Turbine
Countershaft Gear
Countershaft
Turbine Shaft
Drive Shaft / Gear
16e_gearing

16E / 16E-H / 16E-P Spray Gun
19
MAN 96150 EN 01
2.2.5 Wire Grip Mechanism and Drive Roll Carrier
The wire grip mechanism is a piston that forces the drive roll carrier to
grip and start feeding the wire. The piston is actuated by the wire feed
valve on the handle. The turbine, countershaft and lower drive roll turn
continuously whenever the gas head valve is in the run position. The
wire grip mechanism forces the upper drive roll gear to engage the
lower gear and grip the wire. The adjustment screw at the back of the
wire grip mechanism is factory-set and should not be changed. A man-
ual wire grip mechanism is optionally available. (See “14EWGM Man-
ual Wire Grip Mechanism” on page 22.)
2.2.6 Handle and Wire Feed Control
The WIRE FEED ON-OFF control is an air valve that actuates the
automatic wire grip mechanism. If the manual wire grip mechanism is
installed, there is no wire feed control on the handle.
2.2.7 Rear Wire Guide and Snubber
The snubber allows the wire only to feed forward and prevents the
wire from being pulled out the back of the gun. The rear wire guide and
snubber can be changed for different size wires. (See “Hardware
Selection” on page 26.) A strain relief wire guide is also provided
which should be used with brittle wires, such as Metco 405. The strain
relief maintains a radius in the wire to help prevent the wire from
breaking as it enters the gun.
DANGER
Always make sure the
snubber is locked. If the
wire is pulled out of the
rear nozzle while the
gun is lit, the fuel gas
may flash back through
the rear wire guide.
Also, the wire end can
be extremely sharp. If
the wire comes out of
the gun it can cause
personal injury.

16E / 16E-H / 16E-P Spray Gun
20 MAN 96150 EN 01
2.3 Principles of Operation
2.3.1 Mechanical Operation
Except for combustion, all functions of the spray gun are powered by
air pressure and flow. Air pressure drives the turbine and wire drive
mechanisms, enables the wire grip mechanism to feed the wire, cools
the nozzle and air cap and propels the atomized material onto the
workpiece surface. It is essential that proper air pressure and flow be
maintained to the spray gun during operation.
Once the turbine is up to speed, the drive shaft and lower drive roll and
gear are turning. The speed of the turbine is controlled by rotating the
control ring as indicated (i.e., FASTER, SLOWER). Opening the wire
feed valve on the handle actuates the wire grip mechanism. This
engages the upper and lower drive gears to grip and feed the wire.
The wire extends beyond the front of the air cap where it is fully melted
and sprayed.
2.3.2 Combustion
The oxy-fuel gas does not have enough energy, even after combus-
tion, to propel the melted material. When the spray gun is initially lit
(with the gas head valve in the lighting position), there is no air flowing
to the front end. Immediately after the gas is lit, the gas head valve is
set to the run position. In the run position, the oxygen and combustion
gases flow at optimum levels for sustained combustion and air flows to
the air cap. The air flow to the air cap maintains an air envelope
around the flame and the melting wire. The air envelope cools the front
end parts, prevents loading of material on the air cap and propels the
melted material onto the substrate.
16e_cutaway
Air
Oxy-
Wire
127 mm (5”) Minimum
203 mm (8”) Maximum
Air Cap
Body Nozzle Air Cap
Air Envelope
Melting Wire
Characteristic
luminous white
cone of balanced
oxy-acetylene flame
Substrate
Sprayed Material
Atomized Spray
Fuel