9mb manual 37404

9MBPlasma Spray Guns

Instructions

Instruction G37404, Issue e

NOTICE

All personnel responsible for the proper and safe use of thisequipment must read and understand this instruction manual.

In addition, the operator of this equipment must receivepersonal instructions in its use. A thorough understanding ofthe operation, maintenance, and safety requirements of thisequipment is essential.

Copyright 2000Sulzer Metco

Copyright reserved

All rights, including those of translation, reserved. No part of this document may be reproduced in any form without permission in writing from the publisher.

The following trademarks are the property of Sulzer Metco:

AMDRY, BrazBond, Brainware, ChamPro, ChromCoat, Diamalloy, Diamond Jet,Electro-Plasma, HOSP, LinTrav, LPPS, LVPS, Metco, Metcolite, Metcoloy, Metcoseal,MultiCoat, Protal, Roadrunner, RotaPlasma, SmartArc, Sprababbitt, Sprabond Wire,Sprabrass, Sprabronze, Sprasteel, SprayWizard, Sulzer, Sulzer Metco, SUME, TheCoatings Company, ThermoSpray, Triplex, UniCoat, ValuArc, ValuPlaz.

NOTE: The list of trademarks shown above may not be complete and is subject tochange by Sulzer Metco at any time without notice. Refer to the Sulzer Metco TrademarkListing at http://sulzermetco.com/other/trademark.html or contact your Sulzer Metcorepresentative for the latest information. Trademarks and service marks of othercompanies and organizations that appear in this document are the property of theirrespective owners.

SM

MANUFACTURERSDECLARATION

EUROPEAN COMMUNITYCOUNCIL DIRECTIVES

89/392/EEC, 89/336/EEC & 73/23/EECThe Manufacturer: Sulzer Metco

1101 Prospect AvenueWestbury, NY 11590-0201United States of America

declares that the product:Product Name: 9MBHE (Handheld) &

9MBM (Machine-Mounted)Plasma Spray Guns

Product Type: Arc Welding Equipmentconforms to the following applicable Standards:

EN 60204-1 Safety of Machines (Electrical Equipment)pr EN 1050 Risk AssessmentEN 55 011 Group 1, Class A, Conducted Emissions, 150 kHz to 30 MHzEN 55 011 Group 1, Class A, Radiated Emissions, 30 MHz to 1 GHz

EN 61000-4-2 Electrostatic DischargeENV 50140 Radiated ImmunityENV 50204 Radiated Immunity, Pulsed

IEC 801-4 EFT/Burst, Power and I/O LeadsEN 61000-4-11 Voltage Dips & Interrupts, Power Leads

Sulzer Metco hereby acknowledges compliance in accordance with the above listedstandards in the design, manufacture and testing of the above listed equipment.

Director of Equipment OperationsWestbury, New York

January, 1998

9MBPlasma Spray Guns

TABLE OF CONTENTS

Section Title

Safety Measures1 Description

2 Equipment Required3 Optional Equipment4 Installation

5 Operation6 Maintenance7 Disassembly and Assembly8 Recommended Spare Parts9 Replacement Parts

Spraying Tables

Doc. 56348, Issue b PS Safety Measures English (US)

Safety MeasuresFor Plasma Equipment

NOTICE

It is imperative that all personnel responsible forthe installation, operation and maintenance ofthis equipment read and understand the entireSafety Measures section of this instructionmanual prior to working on or using theequipment.

The operator of this equipment must be aware ofall safety precautions and procedures related tothe operation and maintenance of the equipment.

Doc. 56348, Issue b English (US) PS-1

SAFETY MEASURES

GRAPHIC SYMBOL DEFINITIONS

This manual uses a system of graphic symbols to alert the user tothe presence of important operating instructions, safetyconsiderations, and special instructions. These symbols (alongwith their definitions) are shown below.

Additional information of general importance isprovided.

Special instructions, safety instructions, etc. are being presented.

Information, instructions, and restrictions necessary to prevent personal injury or damage to equipment are being presented.

Explosive material is present.

Inflammable material or high temperature is present.

Respiratory equipment must be worn.

English (US) PS-2 Doc. 56348, Issue b

Danger: risk of electric shock.

Toxic material is present.

Ear protection must be worn.

Eye protection must be worn.

Face protection must be worn.

Safety gloves must be worn.

Safety overalls must be worn.

Keep hands, hair, clothing and tools away frommoving parts.


GENERAL

Spraying can be a completely safe process when performed by anoperator who follows the recommended precautionary measures,exercises care in operation, has a proper understanding ofspraying practices, and possesses a knowledge of the equipment.

However, spraying can be hazardous, because it requires the useof combustible gases, hoses under high pressure, potentiallyirritating or toxic spray materials, noise, heat, and UV radiation.It may involve air contaminated by dust, fumes and mists. It isadvisable to remove the operator from the process.

Consult the Sulzer Metco Instruction Manual, Material SafetyData Sheet (supplied with materials), and applicable national andlocal jurisdiction safety and health regulations before using spraymaterials. Some individuals may show unusual sensitivity toexposure to these materials. Failure to observe proper practicesmay result in health hazards.

When safety becomes a habit, the equipment can be used withconfidence.

Magnetic fields from high currents can affect pacemaker operation. Persons wearing electronic life support equipment (Pacemaker) should consult with their doctor before going near spray equipment.

Radiation present.


USE OF EQUIPMENT

Follow the safety measures outlined below, when working withSulzer Metco spraying equipment:

Read, understand, and follow the safety and operationinstructions provided in the instruction manuals.

Never operate equipment if floor of spraying area is wet.

Do not operate equipment above recommended pressures andflows.

Sulzer Metco thermal spray equipment has been expresslydesigned for thermal spraying. Never use it for any other purpose(such as welding, soldering or brazing).

Keep hands and other parts of the body away from hot surfacesand objects. Sprayed metal and surfaces are hot.

Sulzer Metco spray equipment is designed to use only SulzerMetco spare parts. The use of other than Sulzer Metco parts maypose a safety hazard, and will void the warranty.

Equipment Handling

Maintain the equipment in first class condition. Follow themaintenance recommendations in the Sulzer Metco instructionmanuals.

Remember that the stream of sprayed metal is hot. Point the gunaway from yourself and away from materials that will burn.Carelessness in pointing the gun at paper, wood, or oily rags canresult in fire.

Be especially careful not to spray on the hoses, when operatingthe gun. Hoses will burn. Keep them out of the way. Allcompressors, regulators, etc., should be inspected regularly forleaks and loose connections.


REDUCTION OF FIRE AND EXPLOSION HAZARDS

Gases

Fuel gases are highly dangerous. They can asphyxiate, combustor explode.

Follow the safety measures outlined below, when working withfuel gases:

All gas equipment such as fuel gas lines, air lines, compressors,and regulators, should be inspected regularly for leaks and looseconnections.

Maintain proper ventilation where compressed gases are in use.

Route hoses to prevent strain, damage, or contact with oils orgrease.

GAS CYLINDER PRECAUTIONS

The storage, handling, and use of fuel gas cylinders, should be inaccordance with national and local regulations. In addition, thesafety measures outlined below should be followed:

Charged gas cylinders are potentially dangerous. Never put agas cylinder in a hazardous position.

Keep cylinders away from heat and moisture.

Always chain cylinders to keep them from toppling.

Put the valve caps on the cylinders when they are not connectedfor use.

Do not hang a spray gun or hoses on regulators or cylindervalves, because a fire or explosion may result.

Do not set gas cylinder regulators above pressure settingsrecommended by material spray tables in the Sulzer Metcoinstruction manual.

Before moving any cylinder:

- Shut the valve.- Discharge and remove the regulator. - Put on the valve cap.

Use an approved cylinder cart when moving cylinders.


METAL DUST

All dust having considerable calorific value can be explosive.This dust includes flour, starch, hard rubber dust, wood flour,aluminum dust, and dust of other metals. In addition, note thefollowing safety considerations:

Aluminum and magnesium dust are particularly hazardous.Exercise extreme care in handling them.

To minimize the danger of dust explosion resulting fromspraying, adequate ventilation must be provided for spraybooths, and other confined spaces, to prevent the accumulationof fumes and dust.

Inspect and clean regularly to ensure that there is no potentiallydangerous accumulation of dust. Good housekeeping in thework area is essential.

All closed collectors should be provided with blowout holes orrelief panels. All fans, pipes, dust arrestors, and motors shouldbe external to the duct system.

Before cleaning booths, pipes, etc., purge area of any hazardousfumes using the ventilating exhaust system. Ensure thatventilating exhaust system is off while working on it and that analternate means of ventilation is used. Also, keep hands, hair,clothing and tools away from moving parts.

Non-sparking tools should be used in cleaning and repairoperations.

When cleaning, all sources of ignition in the area around thecollector should be eliminated.

When making repairs on the ventilating or dust collectingequipment, no welding or cutting should be done before theequipment is washed down and all metal dust removed.

VENTILATION AND EXHAUST SYSTEMS

A suitable spray booth and an adequate exhaust system arerequired to avoid the toxic or noxious effects of dust, fumes andmists, which may be generated by spraying.

For ordinary spray work, air at a velocity of 300 FPM (90 meters/min) should pass into the opening of the spray booth. With thegun at the booth opening, the exhaust system must be able toexhaust 300 CFM (9 cubic meters/min) of air for every square


foot of booth opening. If the booth has an opening of four squarefeet (.37 square meters), a system that will exhaust 4 x 300 or1200 CFM (33 cubic meters/min) should be provided.

When a console is located outside of the spray booth, the gascabinet ventilation (located on top of the unit) must be ducted intothe spray booth enclosure. In addition, the console has a separateinterlock that should be connected to an exhaust outlet sensor(customer supplied). The interlock will prevent the plasmasystem from operating, when the exhaust system is not inoperation.

If there is any question as to the effectiveness of the ventilationand exhaust system or as to the presence of airborne particles thatthe operator might inhale, consult a competent industrialhygienist.

Sulzer Metco has a complete line of spray booths, dust collectors,and exhaust units.

HAZARDOUS MATERIALS

All Sulzer Metco materials are supplied with a Material SafetyData Sheet. Never spray a material without reading and followingthe precautions contained in the Material Safety Data Sheet.

Some materials (beryllium, tellurium and their oxides, forexample) are very dangerous to the respiratory system and shouldnot be used at all, except under the supervision of a competentindustrial safety engineer.

Blasting, spraying, and finishing all produce dust. Blasting,spraying, and finishing should be considered as hazardous asspraying such materials.

The following materials are specifically listed because they arecommonly sprayed. There are many other hazardous materialsthat are not listed because they are not commonly sprayed.Because standards change and new information becomesavailable from time to time, it is strongly recommended that theinformation contained in the Material Safety Data Sheet, whichcomes with the material being used, be consulted.

Complete and current information should be obtained fromnational and local regulations.


Lead, Lead Alloys, Cadmium and Chromium

The fumes of lead, lead alloys (such as solder and lead basebabbits), cadmium alloys, and chromium alloys are extremelyhazardous. Consult an industrial hygienist for the properprotection.

Zinc, Zinc Alloys, (Zinc, Bronzes and Brasses)

Fumes of these metals are toxic. Consult an industrial hygienistfor the proper protection.

Nickel and Nickel Components

Fumes of nickel components are potentially hazardous. Consultan industrial hygienist for the proper protection. One knownhighly toxic compound is nickel carbonyl. Under certainconditions, nickel carbonyl can be formed by the combination ofnickel and carbon monoxide.

Ozone and Nitric Oxides

The plasma produces small traces of ozone and nitric oxide thatbecome toxic in high concentrations. Exhaust equipment, suitablysized to remove spray dust, will also lower ozone and nitric oxideconcentrations well below permissible limits for continuouspersonnel exposure in the spray area. Exhaust equipmentinadequately sized for complete dust removal may permit toxicconcentrations of ozone or nitric oxide to accumulate.

PERSONAL PROTECTION

Reduction Of Respiratory Hazards

Consult the Sulzer Metco Instruction Manual, Material SafetyData Sheet, and applicable national and local jurisdiction safetyand health regulations (or local standards), before using spraymaterials.

During the spray process, a respirator approved by applicablenational and local regulations should be worn at all times, toprotect the operator from exposure to dust and fumes. Respiratorsshould also be worn when product handling generates dust.Consult an industrial hygienist for the proper protection.

Possible allergic reactions to dust, fumes and the like or otherunknown causes of health impairment due to contact with thebody cannot usually be predicted. To avoid such reaction, neverallow spray dust to enter eyes, mouth, cuts, scratches, or open


wounds. After spraying, and especially before eating or handlingfood, wash hands thoroughly. Wear fireproof or flame resistantprotective clothing.

The particles in the plasma spray stream strike the workpiece athigh velocity, resulting in rebound of sprayed particles. Theworkpiece should be placed far enough inside the spray booth tominimize the amount of particles rebounding out of the booth.Rebound from inside surfaces of the booth itself is usually not aproblem. Where the work cannot be adequately enclosed, higherair velocities may be required.

Any finely divided material may damage the respiratory systemin varying degrees. Whenever fume concentration is high enoughto cause operator discomfort (dizziness, nausea, etc.), stopspraying. Check the ventilating and exhaust systems and relatedequipment. If this equipment is not adequate and not operatingproperly, respirator equipment must be provided. If operatordiscomfort continues, even with the added protection, stopspraying and recheck all equipment. Do not resume sprayinguntil all possibilities of discomfort have been eliminated.

In areas distant from spraying, where no respiratory protectionseems needed, periodic air sampling is recommended.

Air samples should also be taken in the spray area after sprayinghas been stopped. Respiratory protection is not required whenspraying is stopped and area is known to be free of harmful dustand fumes.

Reduction Of Noise Hazards

The operator and other personnel close to the spray operationmust be protected from excessive noise. If possible, the sprayoperation should be in an approved spray cabinet. Hearingprotection (that meets local standards) should be used. Do notrely on wads of cotton for hearing protection. They areineffective against high-intensity noise.

Noise levels at any location depend on such factors as equipmentoperating parameters; background noise; room size; and wall,floor, and ceiling materials. To determine the exact noise level, itis necessary to measure the sound level. The various spray gunscan produce the following maximum noise levels:


ELECTRIC POWER PRECAUTIONS

Never operate equipment if floor of spraying area is wet.

Ensure that adequate power line capacity is provided to avoidelectrical hazards.

If a line cord with a ground lead is provided with the equipmentfor connection to a switchbox, connect the ground lead to thegrounded switchbox. If a cable plug is added for connection to agrounded mating receptacle, the ground lead must be connectedto a safety ground. If the line cord comes with a three pole plug,connect to a grounded mating receptacle. Never remove theground from a plug or use a plug with a broken off ground prong.

Cables

Frequently inspect cables for wear, cracks and damage.Immediately replace those with excessively worn or damagedinsulation to avoid a possibly lethal shock from bare cable.Cables with damaged areas must be replaced.

Keep cables dry, free of oil and grease, and protected from hotmetal and sparks. Do not walk on or drive vehicles over cables.

Terminals, wire raceways, and other exposed parts of electricalunits should have insulating covers secured before operation.

EQUIPMENTMAXIMUM

NOISE LEVEL dB(A)

Plasma Guns 134

High Velocity Oxygen Fuel (HVOF) Guns

142

Thermal Powder Guns 111

Wire Combustion Guns 125

Arc Spray Guns 116


Safety Devices

Safety devices such as interlocks and circuit breakers should notbe disconnected or shunted out.

Before installation, inspection, or service of equipment, shut offall power and remove line fuse (or ensure power switch is lockedor red-tagged) to prevent accidental turning on of power.

Do not open power circuit or change polarity while spraying. If,in an emergency, it must be disconnected, guard against shockburns or flash switch arcing.

Before leaving equipment unattended, always shut off anddisconnect all power from equipment.

A power disconnect switch must be available near the powersource as required by code.

Protection For Wearers of Electronic Life Support Devices (Pacemakers)

Magnetic fields from high currents can affect Pacemakeroperation. Persons wearing electronic life support equipment(Pacemaker) should consult with their doctor before going nearspray equipment.

RADIATION HAZARD

The plasma spray stream emits ultraviolet radiation at a level thatcan cause severe sunburn to skin and eyes. Hands, body and face,including eyes, must be protected when operating the gun. Peoplein the vicinity watching the operator, or working in the area andexposed to the plasma light must be similarly protected.

Body Protection

Any close-mesh garment (shirt or laboratory coat) and gloves will protect the body against ultraviolet burn. For extended spraying, flame-resistant, aluminized coverings are recommended.

Face, Hand and Eye Protection

Welding helmet and gloves are required for adequate protectionof face, hands and eyes.


Radioactive Powders

Aside from ultraviolet, the plasma gun produces no otherradiation such as X-rays, gamma rays or beta rays. However,radiation of this type can occur when spraying radioactivepowders. Whenever radioactive powders are sprayed, fullprecautions must be taken to protect all personnel. Workinvolving radioactive materials should always be done under thesupervision of an expert in the field of radiation safety and inaccordance with recommendations of national nuclear regulatoryagencies.

FLUOROCARBON MATERIAL (O-RINGS)PRECAUTIONS

Sulzer Metco specifies the use of O-rings made of fluorocarbonsynthetic rubber, for use in most Sulzer Metco equipment. Thismaterial provides a wide range of desirable properties, includinghigh flame and heat resistance, resistance to compression-set, andbroad chemical compatibility.

At elevated temperatures above 316 degrees C (600 degrees F),fluorocarbon material may degrade, emitting hydrogen fluoridefumes that, in the presence of water, may react to form highlycorrosive hydrofluoric acid. This can cause severe burns on bareskin with delayed symptoms.

In normal operation of Sulzer Metco gas guns, gun O-ringtemperatures are well below the 316 degrees C (600 degrees F)level at which fluorocarbon O-rings start to degrade. However,the excess heat that occurs in gas guns during prolonged backfire,and in plasma guns when nozzle burnout occurs, may cause O-ring degradation.

Precautions

A heat-degraded fluorocarbon O-ring will look charred orgummy and sticky. To avoid corrosive skin burns, observe theprecautions given below:

1. Put on neoprene or PVC gloves before handling any part con-taminated with heat degraded fluorocarbon O-ring residue.

2. Wash the part thoroughly with soap and water. Fluorocarbonrubber manufactures advise further neutralizing the part withlime-water (calcium hydroxide solution).

3. Discard the gloves when finished.


First Aid

If heat-degraded fluorocarbon rubber contacts bare skin, do thefollowing immediately:

1. Wash skin thoroughly with soap and water.

2. Rub a 2.5% calcium gluconate gel into the skin until anyexisting irritation disappears. If irritation persists, consult aphysician.

DISPOSAL OF MATERIALS AND EQUIPMENT

Disposal of all equipment material and collected overspray shallbe in accordance with local regulations.

Some materials may be classified as hazardous. Follow localrequirements and information on Material Safety Data Sheet.

Some guns may contain a small amount of oil. Drain oil anddispose of per local regulations.

1-1

SECTION 1

DESCRIPTION

Table of Contents

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Modular Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Primary Gas Settings and Insulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Nozzles and Powder Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Dual Powder Port Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Front Gun Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Gun Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Powder Feed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Emergency OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Packaged Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29MBH Handheld Plasma Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39MBHE Handheld Plasma Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39MBM Machine-Mounted Plasma Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

FEATURES

Sulzer Metcos 9MB plasma spray guns are engineered for reliable performance. They producehigh-quality metal, nonmetal, plastic, cermet and ceramic powder coatings.

The following features make these guns suitable for a wide variety of applications:

Modular Construction

Modular gun construction allows for the use of the front gun section with a handle or a machine-mount base. This base in turn can be fitted with several types of extensions. For example, amachine-mounted plasma spray gun with an appropriate base-and-extension setup can applycoatings on hard-to-reach surfaces, such as internal cylinder walls.

Primary Gas Settings and Insulators

The gun can be set to use either argon or nitrogen as the primary plasma gas. All variations of thegun are supplied with an argon front insulator (two gas holes) installed. A nitrogen front insulatoris also furnished (not installed). Both insulators can be used for power levels up to 80 kVA. Anoptional argon front insulator (six gas holes) is also available, providing optimum performance atpower levels between 55 kVA and 80 kVA.

1-2

Nozzles and Powder Ports

Various nozzles and powder ports can be installed on 9MB plasma spray guns to accommodate awide range of spray parameters. One-piece and two-piece nozzles are available. Both kinds ofnozzles produce coatings of superior quality. Two-piece nozzles have a Thin Annular Passage(TAP) cooling design.

Dual Powder Port Hardware

For applications which involve the alternate spraying of two different powders on a repetitivebasis, dual powder port hardware is provided. With dual powder port hardware installed, theproblem of one powder contaminating the feed line or discharge hardware of the other iseliminated.

Front Gun Section

The front gun section is made up of a gun nozzle, a water channeling head and an electrode andinsulator assembly. These components contain passageways for circulating cooling water to thenozzle and electrode.

Gun Handle

The gun handle contains a powder feed switch for starting and stopping the flow of powder. It alsocontains an emergency OFF switch to stop system operations. In the 9MBH plasma spray gun, an18-foot (5.4 m) cable connected to the handle permits hand-held use of the gun up to 15 feet(4.5 m) away from the control unit. In the 9MBHE plasma spray gun, this gun control cable is27 feet (8.2 m) long.

Powder Feed Switch

The powder feed on-off switch is located on the front of the gun handle. It is a trigger-styledouble-action push button. When the gun is properly set up, pressing the switch will initiatepowder flow through the powder port, whether the gun is ignited or not. To stop the powder flow,the switch is pressed again.

Emergency OFF Switch

The emergency OFF switch is located on the left side of the gun handle. It is a normally closed,momentary contacts push button. The emergency OFF switch performs the same function as otheremergency stop controls in the plasma control unit and in other equipment. After the emergencyOFF switch has been pressed, the system must be restarted at the plasma control unit before thegun can be operated again.

1-3

PACKAGED VARIATIONS

Sulzer Metcos 9MB plasma spray guns are available in three packaged variations: the 9MBH, the9MBHE, and the 9MBM.

9MBH Handheld Plasma Spray Gun

The 9MBH handheld gun has a gun handle equipped with a support bracket for suspending thegun. It is suitable for use with Sulzer Metco 9MC, 7MC, or LCP plasma control units. Thefollowing are also included with this gun package:

Cat. No. Description Quantity9MB888 Instruction Manual for 9MB Plasma Spay Guns 1

7M195 Gun Control Cable, 18 feet (5.5 m) long 19MB961 Dual Powder Port Clamp

Includes:Reference 10364 Clamp Screw (1)Reference 37251 Shoulder Screw (2)

1

3M331 Swivel Connector 2

9MB202 Powder Port Stem 2

9MB210 # 2 Powder Port 2

9MB982 # 2 Mounting Block 2

9MB56 Nitrogen Front Insulator (setups with argon or nitrogen as primary plasma gas)

1

9MB730A 730 Nozzle Assembly 1

3M7-GP GP Nozzle Assembly 1

9MB63 63 Electrode Assembly 1

1-4

9MBHE Handheld Plasma Spray Gun

The 9MBHE handheld gun has a gun handle equipped with a support bracket for suspending thegun. It is suitable for use with Sulzer Metco 9MCE or LCPE plasma control units, which conformto CE standards. The following are also included with this gun package:

9MBM Machine-Mounted Plasma Spray Gun

The 9MBM machine-mounted gun has the same package components as the 9MBH, except thatthe 9MBM has a machine-mount base (no gun handle, no gun control cable).

The 9MBM is suitable for use with Sulzer Metco 9MC, 9MCE, 7MC, LCP, or LCPE plasmacontrol units, or as part of a Sulzer Metco MultiCoat or UniCoat system. It is especially wellsuited for integration into robotic systems.

Cat. No. Description Quantity9MB888 Instruction Manual for 9MB Plasma Spay Guns 1

56255 Gun Control Cable, 27 feet (8.2 m) long 19MB961 Dual Powder Port Clamp

Includes:Reference 10364 Clamp Screw (1)Reference 37251 Shoulder Screw (2)

1

3M331 Swivel Connector 2

9MB202 Powder Port Stem 2

9MB210 # 2 Powder Port 2

9MB982 # 2 Mounting Block 2

9MB56 Nitrogen Front Insulator (setups with argon or nitrogen as primary plasma gas)

1

9MB730A 730 Nozzle Assembly 1

3M7-GP GP Nozzle Assembly 1

9MB63 63 Electrode Assembly 1

2-1

SECTION 2

EQUIPMENT REQUIRED

Table of Contents

System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Plasma Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Distribution Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Power Suply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Cooling Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Powder feed Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Hose and Cable Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4MS Flame Spray Safety Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Required Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Cooling Water Purity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Cooling Water Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5DC Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

SYSTEM COMPONENTS

Sulzer Metcos 9MB plasma spray guns require ancillary equipment to supply and control plasmagases, electric power, cooling water and powder. Typically, a complete plasma spray systemincludes the following components:

Description Non-CE Equipment CE Equipment

Plasma Spray Gun 9MBM,9MBH 9MBM, 9MBHE

Plasma Control Unit 9MC, 7MC, LCP 9MCE, LCPE

Distribution Unit 9MCD, LCPD JAM-1010, LCPDE

Power Supply Unit 9MRB, LCPR,PT-810, PT-1110

9MRBE, LCPRE,PT-810/E, PT-1110/E

Cooling Unit 9MK, 8ME FC250, HE300

Powder Feed Unit 9MP, 9MP-CL 9MPE, 9MPE-CL

Gas Regulators 7GH, 7GNR Local Supply

Air Cleaner Unit 4AC Local Supply

Air Control Unit 6A Local Supply

Hose and Cable Unit 7MH 7MH

2-2

In addition, the following Sulzer Metco personal protection equipment is recommended for plasmaspraying operations:

MS Flame Spray Safety Unit

NOTE

For optional equipment and other systemenhancements, refer to the Optional Equipmentsection of this manual.

For a description of Sulzer Metco MultiCoat orUniCoat system components, refer to theappropriate manual.

The following is a brief description of some of these system components. For a more detaileddiscussion of the equipment, refer to the applicable instruction manual.

Plasma Control Unit

The 9MC, 9MCE, ValuPlazTM LCP, or ValuPlazTM LCPE Plasma Control Unit contains allcontrol modules necessary to start and stop the operation of a plasma spray gun and other systemcomponents.

The control unit supplies and continually meters and maintains preset gas flows to the gun, as wellas DC electric power and cooling water used by the gun. It monitors and controls sprayingparameters and sequences system operation, thus permitting repeatable coating results withminimal part rejections. The control unit shuts down the gun automatically in the event that anypressures go below safe operating levels.

Distribution Unit

The 9MCD, LCPD, LCPDE, or JAM-1010 Distribution Unit is a box which receives DC electricpower from the systems power supply unit, and cooling water from the heat exchanger, and sendsboth of these to the plasma spray gun in special water-cooled cables.

Inside the box, a high-voltage circuit generates a controlled high-voltage impulse to establish anelectric arc in the plasma spray gun.

Power Supply Unit

The 9MRB, 9MRBE, LCPR, LCPRE, PT-810, PT-810/E, PT-1110, or PT-1110/E Power SupplyUnit contains rectifiers that convert three-phase plant AC power to the DC power used by theplasma control unit to generate an electric arc in the gun.

Gun parameters such as DC amperage and voltage are set on the plasma control unit depending onthe material (powder) being sprayed. Refer to the Spraying Tables section of this instructionmanual, under the material selected, for the correct values required for the application.

2-3

Sulzer Metco Power Supply Units Maximum Rated DC Output

Sulzer Metcos 9MB plasma spray guns can accommodate a maximum DC electric power supplyof 80 V at 1100 A, in continuous operation mode (100 % duty cycle).

CAUTIONWhen using a power supply unit whose rated DCoutput is higher than the 9MB gun maximum powersupply rating, set the DC voltage and amperagewithin these limits before starting the system, to avoidoverloading the gun. The Spaying Tables in thismanual provide recommended settings for thematerial being sprayed.

Cooling Unit

The HE-300, 8ME, 9MK, or FC250 cooling unit circulates deionized cooling water through theplasma control unit and the plasma spray gun at a sufficient pressure and flow rate to keep theinternal parts of the gun from overheating.

Depending on the quality and temperature of the plant water supply, the cooling unit may be awater-to-water heat exchanger (HE-300, 8ME) or a refrigerated (water-to-refrigerant) heatexchanger (9MK, FC250). If plant water supplied to the system exceeds 65 F (19 C), install arefrigerated heat exchanger.

Powder Feed Unit

The 9MP, 9MPE, 9MP-CL, or 9MPE-CL powder feed unit supplies metered quantities of powderto the discharge port hardware on the tip of the plasma spray gun.

Non-CE Equipment

CE Equipment Voltage Amperage Power

9MRB 9MRBE 80 V 1100 A 88 kW

LCPR LCPRE 80 V 550 A 44 kW

PT-810 PT-810/E 100 V 800 A 80 kW

PT-1110 PT-1110/E 100 V 1000 A 100 kW

2-4

These powder feed units have the following control features:

Hose and Cable Unit

The standard unit is the 7MH Hose and Cable Unit. It includes the following: Two special water-cooled cables (Cat. Nos. 7MH10 for nozzle, and 7MH20 for electrode).

These DC cables are l5 feet (4.5 m) long; each one is surrounded by a transparent braided hosecarrying cooling water.

One plasma gas hose assembly (Cat. No. 7MH50). This hose is 19 feet (5.8 m) long. Instruction sheet.

An optional unit is the 7MH-25 Hose and Cable Unit. It includes the following: Two special water-cooled cables (Cat. Nos. 7MH30 for nozzle, and 7MH40 for electrode).

These DC cables are 25 feet (7.6 m) long; each one is surrounded by a transparent braidedhose carrying cooling water)

One plasma gas hose assembly (Cat. No. 7MH110). This hose is 30 feet (9.1 m) long.

MS Flame Spray Safety Unit

The MS Flame Spray Safety Unit is a package that includes: Helmet with interchangeable lens plates (light and dark welding grades) Aluminized body protector (apron) Aluminized gloves Hearing protectors

The package is designed to protect the operator against the intense visible light, ultravioletradiation, excessive heat, and noise generated by the operation of a plasma spray gun.

Control Feature Non-CE Equipment CE Equipment

Closed-Loop Powder Feed Control 9MP, 9MP-CL 9MPE, 9MPE-CL

Closed-Loop Carrier Gas Control9MP-CL 9MPE-CL

Closed-Loop Air Vibrator Control

2-5

SYSTEM REQUIREMENTS

Required Facilities

A complete plasma spray installation requires plant facilities to supply and control electricalpower, compressed gases, and compressed air that meet the equipments operating specifications.Refer to the Required Facilities section of the applicable plasma control unit or plasma spraysystem manual for details on the following aspects: Location requirements for control unit, power supply unit, and heat exchanger Electric power requirements for control unit, power supply unit, and heat exchanger Plasma gas and compressed air requirements, including gas purity Plant cooling water requirements, including flow, pressure, and temperature of plant water

supplied to the heat exchanger

Cooling Water Purity

To ensure best performance and maximum hardware life, the use of deionized water in aclosed-loop heat exchanger system is recommended to cool the gun. Minerals such as calcium andmagnesium tend to deposit in the water passages of the nozzle and electrode, inside the gun,forming scale, which is a barrier to proper heat transfer.

Water hardness is a measure of the amount of these two minerals present in the water, expressedin parts per million (PPM). An unacceptable level of scale forms in the equipment cooling waterpassages when the total hardness of the water is 100 PPM or greater. Under these circumstances,use of a heat exchanger is required.

Sulzer Metcos two-piece nozzles have a Thin Annular Passage (TAP) cooling design. Because ofthese thinner annular passages, scale will form at a faster rate in TAP cooled nozzles than inconventional one-piece nozzles. One-piece nozzles are likely to have a longer service life in a hardwater environment.

If the cooling water is deionized and circulated in an appropriate heat exchanger, two-piece TAPcooled nozzles will receive more efficient cooling and will tend to have a longer service life thanconventional one-piece nozzles.

Cooling Water Consumption

Cooling water consumption requirements for all 9MB plasma spray guns are as follows:

Inlet Pressure: 125 to 130 psi (8.7 to 9.0 bars)Flow Rate: 3.75 to 4.5 gallons per minute (14.0 to 17.0 l/min)

2-6

DC Power Source

Plasma spray guns require clean, regulated DC power such as is provided by the 9MRB powersupply. (Refer to Sulzer Metco Power Supply Units table in this section for a list of non-CE andCE equipment available.)

WARNINGUSE OF A POWER SUPPLY NOT SPECIFICALLYDESIGNED TO OPERATE A SULZER METCOPLASMA GUN CAN RESULT IN DAMAGE TOTHE GUN AND PERSONAL INJURY.

3-1

SECTION 3

OPTIONAL EQUIPMENT

Table of Contents

Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17MT-2' Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17MST-2' Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Machine Mounts and Cable Connectors for Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Machine Mount for 7MT Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Machine Mount for 7MST Extensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Right-Angle Cable Connector Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Nozzles, Powder Ports, and Powder Port Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Nozzles and Powder Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Swivel Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Quad Powder Port Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Hoses and Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37MH-25 Hose and Cable Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Gun Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Workpiece Cooling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Quad Powder Port Air Jet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Special Gun Mounting and Suspension Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Mounting Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Mounting Adapter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Tool Post Bracket Assembly and Tool Post Fixture Assembly . . . . . . . . . . . . . . . . . . . . . 3-4Hook and Mounting Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Gun Suspension Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Cable Support Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Cable Support Strap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Right-Angle Cable Support Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

EXTENSIONS

Extensions are intended for use with a machine-mount gun only.

7MT-2' Extension

The 7MT-2' Extension is 24 inches (610 mm) long. It can be used to spray the inside of bores assmall as 2 inches (50 mm) in diameter, to a depth of about 18 inches (455 mm). This accessory canbe set up for either angular or straight-ahead spraying. For straight-ahead spraying applications,only standard (straight) nozzles are used in the extension. The package includes instructions.

3-2

7MST-2' Extension

The 7MST-2' Extension is 24 inches (610 mm) long. This accessory can be used to spray theinside of bores as small as 1 5/8 inches (40 mm) in diameter, to a depth of about 13 inches(330 mm). The package includes instructions.

MACHINE MOUNTS AND CABLE CONNECTORS FOR EXTENSIONS

Special assembly and tool packages are available so that a 7MT-2' or 7MST-2' extension can beassembled with a machine-mount base (9MBM with front gun section removed) and connected toform an extension plasma spray gun setup.

Cat. No. 9MB400 Gun Machine Mount for 7MT Extension

This package contains the machine-mount base, special hardware, and tools required to operate a7MT-2' Extension without having procured a 9MBM Plasma Spray Gun.

Cat. No. 9MB500 Gun Machine Mount for 7MST Extension

This package contains the machine-mount base, special hardware, and tools required to operate a7MST-2' Extension without having procured a 9MBM Plasma Spray Gun.

Cat. No. 9MB600 Right-Angle Cable Connector Package

In certain 7MT-2' or 7MST-2' extension setups where the workpiece is long and held in aheadstock, space may be limited. Travel of handling equipment may be impaired, or straight-outcable connections may cause unwanted strain on the water-cooled electric cables. In such cases,the cables and plasma gas hose need to be connected to the machine-mount base at a right angle tothe axis of the gun. This package includes elbows and other parts required for safe and efficientright-angle cable connections, along with instructions.

NOZZLES, POWDER PORTS, AND POWDER PORT HARDWARE

Nozzles and Powder Ports

A wide variety of nozzles and powder ports are available to meet different application needs. For acomplete list of nozzles and powder ports suitable for 9MB plasma spray guns, refer to theReplacement Parts section of this instruction manual, and to the Spraying Tables for hardwaresetup requirements.

Cat. No. 9MB963 Swivel Connector

This 45 stem and swivel connector assembly does not connect the powder hose onto the powderport stem (Cat. No. 3M202). Instead, it screws directly into the mounting block, seating against thepowder port. As a result, powder feed hoses have a lower profile above the 9MB plasma spraygun. This is useful in setups with tight gun clearances.

3-3

Cat. No. 9MB964 Quad Powder Port Clamp

This clamp converts 9MB plasma spray guns from two to four powder ports.

HOSES AND CABLES

7MH-25 Hose and Cable Unit (25 feet / 7.6 m)

This hose and cable set consists of nozzle and electrode water-cooled electric cables, 25 feet(7.6 m) long each, and a plasma gas hose, 30 feet (9.1 m) long.

Cat. No. 9MB199 Gun Control Cable

This cable is 28 feet (7.6 m) long. Used in conjunction with the 7MH-25 cable and hose unit, itallows for effective operation of handheld gun controls when the gun is located up to 25 feet(7.6 m) away from the plasma control unit. For use with 9MBH handheld plasma spray guns only.

WORKPIECE COOLING EQUIPMENT

Cat. No. 9MB950 Quad Powder Port Air Jet Assembly

This assembly contains all parts needed to set up a 9MB plasma spray gun for quadruple-portpowder discharge operation with workpiece cooling capability. It includes an air jet head andpowder port clamp, two adjustable air cooling nozzles, connecting air hoses, hardware, andinstructions.

SPECIAL GUN MOUNTING AND SUSPENSION HARDWARE

The following optional hardware is designed to increase the versatility of both hand-held andmachine-mounted variations of the 9MB plasma spray gun.

Cat. No. 55788 Mounting Bar Assembly

This assembly allows for rotation of the 9MBM machine-mounted plasma spray gun around theaxis of its assembly pin, and for use of the gun with handling equipment.

Cat. No. 7M568 Mounting Adapter Assembly

This assembly, when inserted between Mounting Bar Assembly (Cat. No. 55788) and the 9MBMplasma spray gun machine-mount base, allows for more flexible positioning of the gun. A 360rotation of the gun is made possible with this setup.

3-4

Cat. No. 7M90 Tool Post Bracket Assembly andCat. No. 6P125 Tool Post Fixture Assembly

These accessories allow for machine-mount setups of the 9MBH and 9MBHE handheld plasmaspray guns without extensive disassembly of parts.

See Figure 9.11 in the Replacement Parts section of this manual. In the tool post bracket assembly,the Tool Post Bracket (Reference 15455) attaches to the top of the gun body in place of the eyesupport bracket. The Tool Post Bracket Stud (Reference 14945) fits into a hole in the Tool PostCross Bar (Reference 1675) of the tool post fixture assembly, which in turn attaches to the toolpost of a lathe.

Cat. No. 55789 Gun Hook and Mounting Block

This assembly is used to suspend the 9MBH or 9MBHE handheld plasma spray gun. It includes aninsulated hook, a mounting block, and fasteners.

Cat. No. 9MB266 Gun Suspension Assembly

This tool balancer is used to support the weight of the 9MBH or 9MBHE handheld plasma spraygun. It includes a spring-loaded, extendible cable which hooks into the eye of the support bracketat the top of the gun. The gun hangs from the cable, directly in front of the spray booth. Thepackage includes instructions for installation and adjustment.

CABLE SUPPORT HARDWARE

Cat. No. 7M301 Cable Support Strap Assembly

This assembly is used in conjunction with a 9MBM plasma spray gun machine-mount baseassembly (Cat. No. 9MB165) or with a gun machine mount for a 7MT or 7MST extension, insetups that allow for the straight-out connection of water-cooled cables and plasma gas hose.

Cat. No. 7M605 Right-Angle Cable Support Bracket Assembly

This assembly is used in conjunction with a 9MBM plasma spray gun machine-mount baseassembly (Cat. No. 9MB165) or with a gun machine mount for a 7MT or 7MST extension, insetups where the water-cooled cables and the plasma hose are connected at a right angle to the axisof the gun.

4-1

SECTION 4

INSTALLATION

Table of Contents

System Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Hose and Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

9MBH or 9MBHE Handheld Plasma Spray Gun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39MBM Machine-Mounted Plasma Spray Gun with Cable Support Strap . . . . . . . . . . . . . 4-69MBM Machine-Mounted Plasma Spray Gun with Voltage Divider . . . . . . . . . . . . . . . . 4-8

SYSTEM HOOKUP

Installation of Sulzer Metcos 9MB plasma spray guns involves connecting hoses and cablesbetween the gun and a control unit, and between the gun and a powder feed unit.

WARNING

BECAUSE OF HIGH VOLTAGES PRESENT INTHE SYSTEM, ALL INSTALLATION WORKMUST BE DONE BY QUALIFIED SULZERMETCO FIELD SERVICE PERSONNEL.

All variations of the 9MB plasma spray gun, the 9MBH and 9MBHE handheld guns and the9MBM machine-mounted guns, are supplied with dual powder port hardware.

All 9MB guns require the connection of two water-cooled electric cables and one plasma gas hosebetween the gun and the plasma control unit. The water-cooled electric cables and the plasma gashose are supplied in the following packages:

7MH Hose and Cable Unit, including two cables 15 feet (4.5 m) long and one plasma gashose 19 feet (5.8 m) long 7MH-25 Hose and Cable Unit, including two cables 25 feet (7.6 m) long and one plasmagas hose 30 feet (9.1 m) long (optional)

In addition, one or more powder feed hoses must be connected between the gun and the powderfeed unit. The necessary powder feed hoses are supplied with each powder feed unit.

4-2

Also, when installing a 9MBH or 9MBHE handheld gun, a gun control cable must be connectedbetween the gun and the control unit. An 18-foot (5.5 m) long gun control cable is supplied withthe 9MBH gun. An optional 28-foot (8.5 m) long gun control cable is available for the 9MBH gun.A 27-foot (8.2 m) long gun control cable is supplied with the 9MBHE gun.

To connect the required hoses and cables to the gun, proceed as follows:

NOTE

To complete the hose and cable connections to theplasma control unit, refer to the control units instructionmanual.

To complete the powder feed hose connections to thepowder feed unit, refer to the powder feed unitsinstruction manual.

GROUNDING

Check the plasma spray system for proper DC grounding. The DC+ circuit must be grounded inonly one place.

CAUTION

Grounding the DC+ circuit in more than one placewill cause errors in current readings and can alsodamage the equipment.

NOTE

It is generally best to ground the DC+ output terminal atthe power supply unit. Sulzer Metco LCPR and 9MRBpower supply units have an internal chassis groundconnection for their positive (+) DC output terminals.

If such grounding connection is not provided (as in the9MR and 9MRU power supply units), it is recommendedto install a #8 AWG (3.7 mm OD) ground wire betweenthe DC+ output terminal and the chassis of the powersupply unit.

Using an ohmmeter, check for a good ground between the DC+ output terminal in the powersupply unit and the AC input ground terminal.

4-3

WARNING

THE 9MBM MACHINE-MOUNTED PLASMASPRAY GUN MUST BE ISOLATED FROM THEGUN MANIPULATOR TO PROTECT AGAINSTELECTRICAL SHOCK HAZARD.

HOSE AND CABLE CONNECTIONS

WARNING

BEFORE PERFORMING ANY INSTALLATIONWORK, DISCONNECT ALL ELECTRICALPOWER FROM THE SYSTEM.

9MBH or 9MBHE Handheld Plasma Spray Gun

To connect the required hoses and cables to a 9MBH or 9MBHE handheld plasma spray gun,proceed as follows:

1. Install the powder port hardware on the gun. (Refer to the Disassembly and Assembly sectionof this manual.)

2. Connect either end of one powder feed hose (one hose supplied with each powder feedhopper) to the powder port stem in the powder port hardware. For dual powder feeds, connectthe second powder feed hose in the same way to the second powder port stem in the dualpowder port hardware supplied with all 9MB plasma spray guns (see Figure 4.1). Forquadruple powder port feeds, connect the third and fourth powder feed hoses to the third andfourth powder port stems in the quad powder port hardware (optional Quad Powder PortClamp, Cat. No. 9MB964, or Quad Powder Port Air Jet Assembly, Cat. No. 9MB950).

3. Unscrew the insulators (Cat. No. 7MH32) from both threaded posts at the bottom of the gunhandle to expose the cable fittings and the markings on the posts.

NOTE

See Figure 4.1. The forward post is marked NOZ+ andhas right-hand threads on the cable fitting. The rear post,marked EL-, has left-hand threads on the cable fitting.

4. Using the nozzle water-cooled electric cable (with fittings marked NOZ+ at each end), slideone of the insulators, smooth narrow bore end first, over one end of the cable, far enough toexpose the fitting nut.

5. Connect the nozzle water-cooled electric cable to the gun cable fitting marked NOZ+(right-hand thread). Tighten using two wrenches, one on the cable fitting and one on the gunpost fitting.

4-4

6. Screw the internal thread of the insulator to the wider external thread of the nozzle post(NOZ+).

7. Using the electrode water-cooled electric cable (with fittings marked EL- at each end), slidethe remaining insulator, smooth narrow bore end first, over one end of the cable, far enough toexpose the fitting nut.

8. Connect the electrode water-cooled electric cable to the gun cable fitting marked EL-(left-hand thread). Tighten using two wrenches, one on the cable fitting and one on the gunpost fitting.

9. Screw the internal thread of the insulator to the wider external thread of the electrode post(EL-).

WARNING

BOTH INSULATORS MUST BE IN PLACE TOPROTECT AGAINST ELECTRIC SHOCKHAZARD.

CAUTION

Keep the water-cooled cables out of puddles andseparated from each other to prevent leakage ofhigh-frequency voltage and possible faulty ignition.

10. See Figure 4.1. Remove the thread protector from the free end of the front gun body hoseassembly (plasma gas pigtail) at the bottom of the gun handle. Using the end of the plasmagas hose with the smaller fitting nut, connect this fitting nut to the hose fitting on the plasmagas pigtail. Tighten using two wrenches, one on the hose fitting and one on the pigtailfitting.

CAUTION

Before connecting the gun end of the plasma gas hoseto the gun, make sure that the front gun body hoseassembly (plasma gas pigtail) is tightly connected tothe fitting at the bottom of the gun handle.

11. See Figure 4.1. Remove the thread protector from the free end of the cable and switchassembly (electrical pigtail) at the bottom of the gun handle. Connect the female connectoron the gun control cable to the cable receptacle male connector on the electrical pigtail.

4-5

Figure 4.1 9MBH or 9BMHE Handheld Plasma Spray Gun Installation

POWDER FEEDHOSES

NOZZLE (NOZ+)WATER-COOLEDELECTRICAL CABLE HERE

INSULATORAND CONNECT

REMOVEREMOVEINSULATOR

AND CONNECTELECTRODE (EL-)WATER-COOLED

ELECTRICAL CABLE HERE

PLASMA GASPIGTAILELECTRICAL

PIGTAILREMOVE THREADPROTECTOR AND CONNECT PLASMA

REMOVE THREADPROTECTOR AND

CONNECT GUNCONTROL CABLE HERE

GAS HOSE HERE

4-6

9MBM Machine-Mounted Plasma Spray Gun with Cable Support Strap

To connect the required hoses and cables to a 9MBM machine-mounted gun with an optional Cable Support Strap Assembly (Cat. No. 7M301) and current connection insulators (Cat. No. 7M144), proceed as follows:



3. Using the nozzle water-cooled electric cable (with fittings marked NOZ+ at each end), slidea current connection insulator (Cat. No. 7M144) over one end of the cable, far enough toexpose the fitting nut.

4. Insert the end of the nozzle cable with the insulator through the lower hole in the cable supportstrap (see Figure 4.2).


6. Using the electrode water-cooled electric cable (with fittings marked EL- at each end), slidea current connection insulator over one end of the cable, far enough to expose the fitting nut.

7. Insert the end of the electrode cable with the insulator through the upper hole in the cablesupport strap (see Figure 4.2).


9. Slide both current connection insulators over the cable fittings and over the gun fittings, so thatno part of the connecting fittings is exposed.

WARNING

CURRENT CONNECTION INSULATORS MUSTBE IN PLACE TO PROTECT AGAINSTELECTRICAL SHOCK HAZARD.

4-7

CAUTION

Keep the water-cooled cables out of puddles andseparated from each other to prevent leakage ofhigh-frequency voltage and possible faulty ignition.

10. Using the end of the plasma gas hose with the smaller fitting nut, connect this fitting nut to theplasma gas hose fitting on the gun (see Figure 4.2). Tighten using two wrenches, one on thehose fitting and one on the gun fitting.

Figure 4.2 9MBM Machine-Mounted Plasma Spray GunInstallation with Cable Support Strap

9MBM Machine-Mounted Plasma Spray Gun with Voltage Divider

NOTE

The Voltage Divider (Cat. No. 9MCD600) is suppliedonly with a Sulzer Metco 9MCD Distribution Unit. See9MC Plasma Control Unit instruction manual fordescription and replacement parts.

NOZZLE (NOZ+) WATER-COOLEDELECTRIC CABLE(INSULATOR IN PLACE)

ELECTRODE (EL-) WATER-COOLEDELECTRIC CABLE(INSULATOR IN PLACE)

CABLE SUPPORTSTRAP

PLASMA GAS HOSE

4-8

To connect the required hoses and cables to a 9MBM machine-mounted gun with a voltagedivider, proceed as follows:



3. Using the nozzle water-cooled electric cable (with fittings marked NOZ+ at each end), slidea current connection insulator (Cat. No. 7M144) over one end of the cable far enough toexpose the fitting nut.


5. Slide the current connection insulator over the connected cable and gun fittings, so that no partof the connecting fittings is exposed.

WARNINGTHE CURRENT CONNECTION INSULATORMUST BE IN PLACE TO PROTECT AGAINSTELECTRICAL SHOCK HAZARD.

6. Dismantle the voltage divider, maintaining the orientation of each part. Unscrew the flaredclamp nut from the housing, exposing the split ring. Pull out the split ring, leaving the O-ringin place. Using the electrode water-cooled electric cable (with fittings marked EL- at eachend), slide the clamp nut, flared end first, then the split ring with O-ring in place, then thehousing of the voltage divider over one end of the cable, far enough to expose the fitting nut.


8. Slide the voltage divider housing over the connected fittings. Insert the front shoulder end ofthe housing into the locking ring (Cat. No. 9MB142) in the rear of the 9MBM gunmachine-mount base assembly, using a pushing and twisting motion.

NOTEPosition the voltage divider housing so that the redpositive gun reference lead (marked +) is on top,as shown in Figure 4.3.

4-9

9. When the shoulder of the voltage divider housing is seated against the locking ring of the gunmachine-mount base assembly, push the split ring into the rear fitting end of the housing as faras it will go.

10. Screw the clamp nut on the external thread of the split ring, then on the external thread of thefitting end of the voltage divider housing, hand tight. This secures the assembly in place.

11. Remove one of the mounting screws on top of the gun machine-mount base assembly, nearestthe red positive gun reference lead (marked +), and replace it with the gun terminal adapterscrew (Cat. No. 9MCD601, supplied with the voltage divider). Insert the terminal screw (Cat.No. 9MCD632, also supplied with the voltage divider) into the recessed head of the gunterminal adapter screw, and screw it in part way. Position the wire terminal of the positive gunreference lead between the terminal screw and the gun terminal adapter screw, then secure theconnection by tightening the terminal screw (see Figure 4.3).

12. Using the end of the plasma gas hose with the smaller fitting nut, connect this fitting nut to theplasma gas hose fitting on the gun (see Figure 4.3). Tighten using two wrenches, one on thehose fitting and one on the gun fitting.

Figure 4.3 9MBM Machine-Mounted Plasma Spray GunInstallation with Voltage Divider

TERMINAL ADAPTER SCREW

POSITIVE GUN REFERENCELEAD (MARKED +)

TERMINAL SCREW

VOLTAGEDIVIDER

NOZZLE (NOZ+)WATER-COOLEDELECTRIC CABLE(INSULATOR IN PLACE)

PLASMA GAS HOSEELECTRODE (EL-)WATER-COOLEDELECTRIC CABLE

5-1

SECTION 5

OPERATION

Table of Contents

Gun Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1System Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29MB and 9MBH Handheld Plasma Spray Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Operating the Powder Feed ON-OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Operating the Emergency OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

9MBM Machine-Mounted Plasma Spray Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3System Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

GUN CONTROL

Except for the gun handle control switches in the 9MBH or 9MBHE handheld variations, theoperation of Sulzer Metcos 9MB plasma spray guns is controlled from the plasma control unit.

For detailed instructions on the operation of the gun in a specific plasma spray system, refer to theapplicable plasma control unit instruction manual.

WARNING

BEFORE OPERATING THE EQUIPMENT, THEOPERATOR MUST BE THOROUGHLYFAMILIAR WITH THE SAFETY MEASURESOUTLINED AT THE FRONT OF THIS MANUAL.

CAUTION

Before starting operation, be sure that allhardware installed in the gun (nozzle, powderports, front insulator) is correct for the powder tobe sprayed and the primary plasma gas to beused. The use of improper gun hardware canresult in poor gun operation, and can adverselyaffect coating quality.

5-2

SYSTEM STARTUP

Complete all preliminary system startup procedures, up to and including the gun ignition cycle.Refer to the applicable plasma control unit instruction manual.

9MBH AND 9MBHE HANDHELD PLASMA SPRAY GUNS

There are two switches on the gun handle of the 9MBH and 9MBHE plasma spray guns: Powder Feed ON-OFF Switch. Emergency OFF Switch

These switches enable the operator to control spraying operations from the handheld gun.

Operating the Powder Feed ON-OFF Switch

The powder feed ON-OFF switch is located on the front of the gun handle. It is a trigger-style,double action push-button switch.

To start spraying, press the powder feed ON-OFF switch once. This will initiate powder flowthrough the powder ports.

To stop spraying, press the powder feed ON-OFF switch again. This will stop the powder flow.

NOTE

The powder feed ON-OFF switch only starts and stopsthe powder flow. Ignition and other functions arecontrolled from the plasma control unit. Refer to theappropriate plasma control unit or spray systeminstruction manual.

Operating the Emergency OFF Switch

The emergency OFF switch is located on the left side of the gun handle. It is a normally closed,momentary contacts push-button switch.

To stop the plasma system immediately from the handheld gun, press the emergency OFFswitch. Except for emergency conditions, such as a nozzle water leak or an excessively highvoltage or amperage reading, the emergency OFF switch should not be used to shut down anoperating gun. Follow the normal shutdown procedure as described in the applicable plasmacontrol unit instruction manual.

5-3

NOTE

Once the emergency OFF switch is activated, the systemmust be restarted at the console before the gun can beoperated again. Refer to the appropriate plasma controlunit or spray system instruction manual.

CAUTION

Pressing the emergency OFF switch during a plasmaspraying operation could result in clogged powderfeed hoses. Clean hoses before restarting the system.

9MBM MACHINE-MOUNTED PLASMA SPRAY GUNS

In 9MBH machine-mounted spray gun setups, there are no operating controls at the gun. Allsystem startup, shutdown, powder feed and emergency stop controls are at the plasma control unit.Refer to the applicable plasma control unit instruction manual.

SYSTEM SHUTDOWN

To shut down the plasma spray system at the end of a shift, follow the shutdown procedureoutlined in the applicable plasma control unit instruction manual.

6-1

SECTION 6

MAINTENANCE

Table of Contents

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Avoiding Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4General Gun Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Water-Cooled Electric Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

TROUBLESHOOTING

WARNING

BEFORE PERFORMING ANY ASSEMBLY,DISASSEMBLY OR ADJUSTMENT OF ANYPART OF A 9MB GUN INSTALLED IN A PLASMASPRAY SYSTEM, DISCONNECT ALL ELECTRICPOWER FROM THE SYSTEM.

CAUTION

Before starting operation, be sure that allhardware installed in the gun (nozzle, powderports, front insulator) is correct for the powder tobe sprayed and the primary plasma gas to beused. The use of improper gun hardware canadversely affect the coating.

The following troubleshooting chart is provided so that, in the event of a gun malfunction, its usercan quickly and accurately isolate and correct the trouble. This chart is intended for qualifiedpersonnel, thoroughly familiar with the safety precautions, system controls, handheld gun controls,operating procedures and maintenance activities related to Sulzer Metcos 9MB plasma sprayguns.

6-2

In the event that the malfunction cannot be cleared after using the troubleshooting chart, contactSulzer Metco Field Service for further assistance.

TROUBLESHOOTING CHART

Trouble Isolation Solution

Gun does not light. Refer to the plasma control units instructionmanual, and use test ignition procedure tocheck for a good spark at gun tip.

Check condition of all gun hardware.

Verify that correct front insulator and otherhardware are installed.

Verify that hardware is properly assembled.

Check the points gap, change if necessary

Clean excess deposits on tip of electrodewith abrasive pad (Scotch-Brite)

Change hardware if necessary.

Make sure nozzle and electrode are properlyseated and locked in place.

Gun lights up andimmediately shuts off,when using nitrogen gas.

Check water channeling head for tightconnection.

Check for eroded hardware and proper gunassembly.

Check plasma control unit (refer toappropriate instruction manual.)

Tighten if necessary.

Replace nozzle or electrode if necessary.Refer to Disassembly and Assembly sectionin this manual.

Check safety shut-offs as described ininstruction manual.

Gun lights, but shuts offwhen moved.

Check for faulty water-cooled electriccables.

Check handheld gun emergency OFF switchand gun control cable.

Check plasma control unit (refer toappropriate instruction manual).

Check if voltage drop across cables isdifferent when cables are bent.

Replace emergency OFF switch ifnecessary. Check continuity of gun controlcable, and change if necessary.

Check safety shut-offs as described ininstruction manual.

Gun sparks when ittouches a groundedobject (gun suspensionhook, tool post mountingstud, etc.).

Check for a short to ground, from electrodewater-cooled electric cable connection ongun to ground or to plasma control unit.

Make sure power supply unit is grounded.See Grounding in Installation section of thismanual.

Gun spurts copper,damages nozzle.

Check for gun water leaks.

Check for water in plasma gas hose. Check plasma control unit (refer to

appropriate instruction manual).

Check O-rings, nozzle and electrode, andreplace as needed.

Purge lines and check gases. Check lighting current at plasma control

unit, and adjust if too high.Gun leaks water. Check all gun O-rings (see Note).

Check for water in plasma gas hose.

Check O-rings, nozzle and electrode, andreplace as needed.

Purge lines and check gases.

Gun goes on and offcontinuously, duringignition, when usingnitrogen gas.

Verify that water channeling head is tightand properly seated.

Verify that correct hardware is installed andproperly assembled.

Check for faulty insulator.

Tighten channeling head if necessary (referto Disassembly and Assembly section in thismanual).

Check manual for correct hardware andassembly.

Replace insulator if necessary.

6-3

Gun leaks gas. Check plasma gas hose connection tohandheld gun plasma gas pigtail.

Check all O-rings (see Note).

Tighten plasma gas hose connection.

Replace O-rings as needed.

Cracked nitrogen gasring (marked N) on frontinsulator.

Check gas supply to gun. Check gas connections for leaks. Check gas purity (no water). Replace front nitrogen insulator.

Poor nozzle life. Visually check nozzle in gun installation.

Check nozzle (TAP cooled): a black coatingon the water-cooled surfaces indicates a highconcentration of oxygen or ions in the water,which reduces nozzle life.

Check nozzle (TAP cooled): a white-graycoating on the water-cooled surfacesindicates a high concentration of minerals inthe water, which reduces nozzle life.

Check water pressure and flow. Waterpressure to gun should be 130 psi (9.0 bars),for a flow rate of 3.75 gals/min (14 l/min)minimum.

Check cooling water temperature. Thetemperature of water circulating through thegun should be no more that 65 F (19 C).

Observe plasma spray stream. Except whenspraying copper or chromium powders, theappearance of a green color in the plasmaflame indicate an excessively worn nozzle.

Do not start gun if water droplets can beobserved in nozzle bore. (This will causesevere nozzle gouging when in operation.)

Drain water in cooling unit and water lines.Add distilled, deionized water. For 9MK or8ME unit, insert a fresh water conditionerchemical element in cooling unit.

Drain water in cooling unit and water lines.Add distilled, deionized water. For 9MK or8ME unit, insert a fresh water conditionerchemical element in cooling unit.

Adjust water pressure and flow rate asrequired. (Refer to cooling unit instructionmanual.)

If water exceeds 65 F (19 C), install arefrigerated heat exchanger.

Stop spraying and inspect nozzle. Changenozzle if necessary.

Poor electrode life. Check electrode periodically.

Check voltage and amperage readings onplasma control unit. Excessive voltage oramperage can accelerate electrode wear.

Check water pressure and flow. Waterpressure to gun should be 130 psi (9.0 bars),for a flow rate of 3.75 gals/min (14 l/min)minimum.

Check cooling water temperature. Thetemperature of water circulating through thegun should be no more that 65 F (19 C).

Observe plasma spray stream. Bright, whitesparks and streamers in the plasma flameindicate an excessively worn electrode.

Check gas quality. Plasma gases containingimpurities accelerate electrode wear.

If the tip of the electrode has a concavecrater with a diameter of more than 1/8 inch(3 mm), replace electrode.

Adjust voltage and amperage according toparameters specified in the Spraying Tablesfor the material being sprayed.

Adjust water pressure and flow rate asrequired. (Refer to cooling unit instructionmanual.)

If water exceeds 65 F (19 C), install arefrigerated heat exchanger.

Stop spraying and inspect electrode. Changeelectrode if necessary.

Use of pre-purified plasma gases improveselectrode life.

High operating voltage. Check plasma gas quality. Moisture in gascan cause a higher voltage.

Replace with pre-purified plasma gas.

Low operating voltage. Check gun hardware, and for worn nozzleand electrode.

Check gas supply.

Correct hardware must be installed forparameters of material being sprayed.

Check gas connections for leaks, and thatproper gas is being used.

Trouble Isolation Solution

6-4

NOTE

When examining O-rings, be sure to inspect the conditionand assembly of Water Channeling Head O-Ring (Cat.No. 9MB297). This is a cemented O-ring. (Refer to theDisassembly and Assembly section of this manual.)

AVOIDING TROUBLE

General Gun Care

Many problems can be avoided by careful handling of the gun and its parts. The followingpractices should be observed:

1. Keep nozzles and electrodes in their protective containers when not in use.

2. Do not mar or damage parts when installing or disassembling.

3. Do not use excessive force to tighten assemblies. Where hand tightening is called for, do notuse tools.

4. Use the proper tools for each job. Where special tools are called for or supplied, use them.5. Before disassembling, wipe the gun (or parts being worked on) to clean off any accumulation

of dirt or dust. This will prevent dirt from getting into critical areas.

NOTEIn general, when replacing gun parts, the associatedO-rings should be changed also.

O-Rings

When parts of a gun are disassembled, always inspect the condition of any O-rings, as well as theirmating surfaces. O-rings that exhibit nicks, cuts, or flat spots should be replaced.

Nozzles

Although 9MB gun nozzles are designed to provide exceptionally long service life, certainpractices can prevent premature wear.

1. Do not start the gun if water droplets can be observed in the nozzle bore. Water in the nozzlebore will cause severe gouging of the nozzle during operation. Using the Purge control on theplasma control unit, purge gas through the gun to clear out any water after changing thenozzle. (Refer to the appropriate plasma control unit instruction manual.)

6-5

2. Nozzle service life can be prolonged by rotating the nozzle about 90 every four hours of gunoperation.

NOTE

An orientation mark on the nozzle will aid in determiningrotation sequence.

3. Except when spraying powders containing copper or chromium, the appearance of a greencolor in the plasma flame may indicate an excessively worn nozzle. Stop spraying and inspectthe nozzle. Replace as required.

Electrodes

1. Periodically examine the condition of the electrode. If the tip of the electrode has a concavecrater with a diameter of more that 1/8 inch (3 mm), replace the electrode.

2. Bright, white sparks and streamers in the plasma flame indicate an excessively erodedelectrode. Stop spraying and inspect the electrode. Replace the electrode as required.

Water-Cooled Electric Cables

Keep the water-cooled electric cables out of water puddles and separated from each other. Wateron the cable jackets can cause leakage of high-frequency voltage, resulting in faulty gun ignition.

Periodically check all hoses and cables. If the hoses or their fittings are worn or damaged, theymust be replaced.

Lubrication

1. Always lubricate O-rings and O-ring seats with a light coating of Sulzer Metco RinglubeLubricating Compound (Cat. No. 2M182) before reassembly.

2. Do not use too much Ringlube when installing nozzles.

3. Do not allow any Ringlube to remain inside the nozzle bore. Deposits of Ringlube in a nozzlebore encourage rapid deterioration of the nozzle.

6-6

Cleaning

WARNING

TO PREVENT INJURY, SHUT OFF ALLELECTRIC POWER TO THE GUN BEFORECLEANING THE NOZZLE OR THE POWDERPORTS.

When spraying continuously for a half hour or more, an accumulation of powder may form on thenozzle face and at the exit orifice of each powder port. Such accumulations should be removed atregular intervals, using a clean, dry, lint-free cloth to wipe off the material.

CAUTION

Do not scrape or file off the accumulations, or damageto the gun may result.

7-1

SECTION 7

DISASSEMBLY AND ASSEMBLY

Table of Contents

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Standard Tools and Shop Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Special Tools and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

9MB Plasma Spray Gun Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Front Gun Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Water Channeling Head Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5Water Channeling Head Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7Nozzle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8Nozzle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8Electrode and Insulator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9Electrode and Insulator Assembly in Handheld Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9Electrode and Insulator Assembly in Machine-Mounted Guns . . . . . . . . . . . . . . . . . . . . . 7-11Electrode and Insulator Assembly Disassembly and Assembly . . . . . . . . . . . . . . . . . . . 7-13Electrode replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Gun Handle (Handheld Guns Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15Removing Front Gun Section from Gun Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15Gun Handle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15Front Gun Body and Front Gun Body Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16Rear Gun Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18Switch and Cable Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19Gun Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20Installing Front Gun Section into Assembled Gun Handle . . . . . . . . . . . . . . . . . . . . . . . . 7-21Installing Front Gun Section into Disassembled Gun Handle . . . . . . . . . . . . . . . . . . . . . . 7-22

Machine-Mount Base (Machine-Mounted Guns Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23Locking Ring Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23Electrode Holder Clamp and Hose Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24Mounting Stud and Hose Fitting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26Plasma Gas Hose Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

Powder Port Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27Installing Dual Powder Port Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27Powder Port Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

7-2

TOOLS REQUIRED

The following are required to perform disassembly and assembly of Sulzer Metcos 9MB plasmaspray guns:

Standard Tools and Shop Materials

Special Tools and Lubricants

9MB PLASMA SPRAY GUN CONSTRUCTION

Normal operation of Sulzer Metcos 9MB plasma spray guns involves the replacement of variousparts and assemblies of the gun. Familiarity with the proper procedures for disassembly andassembly of the gun will help maximize the guns service life and performance.

WARNING

BEFORE PERFORMING ANY ASSEMBLY,DISASSEMBLY OR ADJUSTMENT OF ANYPART OF A 9MB GUN THAT IS INSTALLED IN APLASMA SPRAY SYSTEM, DISCONNECT ALLELECTRICAL POWER FROM THE SYSTEM.

Quantity Description2 Adjustable wrench (or appropriate pliers)1 Flat blade screwdriver

1 Solvent

1 Locquic Primer Grade T (or equivalent)1 Loctite Sealant 242 (or equivalent)

Quantity Cat. No. Description1 10MB104 Electrode Nut Spanner

1 7MB105 Electrode Puller Pliers

1 9MB852 Nozzle Wrench (required for two-piece nozzle)1 55866 Nozzle Nut and Locking Ring Wrench

1 2M182 Ringlube Lubricating Compound

7-3

For purposes of disassembly and assembly, Sulzer Metcos 9MB plasma spray guns can bedivided into three main sections: Front gun section Gun handle or machine-mount base Powder port hardware

WARNINGDURING DISASSSEMBLY AND ASSEMBLY OF ASUSPENDED HANDHELD OR AN INSTALLEDMACHINE-MOUNTED PLASMA SPRAY GUNWITH THE PLASMA GAS HOSE STILLCONNECTED TO IT, RESIDUAL COOLINGWATER IN THE GUN CAN TRICKLE INTOEXPOSED PLASMA GAS PASSAGES AND DOWNTHE PLASMA GAS HOSE. WHEN THE GUN ISLIGHTED AFTER REASSEMBLY, THIS WATERIS FORCED UP THE PLASMA GAS HOSE INTOTHE GUN, CREATING AN EXPLOSIVEMIXTURE WHICH WILL DAMAGE THE ENTIREFRONT GUN SECTION AND MAY CAUSEINJURIES.TO PREVENT THIS, TAKE ONE OF THEFOLLOWING PRECAUTIONS:1. DISCONNECT PLASMA GAS HOSE BEFORE

DISASSEMBLY.2. LIFT AND SUSPEND PLASMA GAS HOSE

ABOVE THE GUN DURING DISASSEMBLYAND ASSEMBLY.

FRONT GUN SECTION (See Figure 7.1)

The front gun section includes the following assemblies:

Nozzle

Water channeling head

Electrode and insulators assembly

7-4

Figure 7.1 9MB Plasma Spray Guns Front Gun Section

FRONT GUN SECTION

NOZZLE

WATER CHANNELING HEAD

ELECTRODE AND INSULATOR ASSEMBLYGUN HANDLE

FRONT GUN SECTION

NOZZLE

WATER CHANNELING HEAD

MACHINE-MOUNT BASEELECTRODE AND INSULATOR ASSEMBLY

9MBH AND 9MBHE HANDHELD GUNS

9MBM MACHINE-MOUNTED GUN

7-5

To remove the front gun section, proceed as follows:

9mb manual 37404

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