9MB Manual 37404

BULZER NETCO
9MB
Plasma Spray Guns
Instructions
Instruction G37404, Issue e
NOTICE
All personnel responsible for the proper and 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 essential.
Copyright 2000
Sulzer 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, The
Coatings Company, ThermoSpray, Triplex, UniCoat, ValuArc, ValuPlaz.
NOTE: The list of trademarks shown above may not be complete and is subject to
change by Sulzer Metco at any time without notice. Refer to the Sulzer Metco Trademark
Listing at http://sulzermetco.com/other/trademark.html or contact your Sulzer Metco
representative for the latest information. Trademarks and service marks of other
companies and organizations that appear in this document are the property of their
respective owners.
SM
MANUFACTURERS
DECLARATION
EUROPEAN COMMUNITY
COUNCIL DIRECTIVES
89/392/EEC, 89/336/EEC & 73/23/EEC
The Manufacturer: Sulzer Metco
1101 Prospect Avenue
Westbury, NY 11590-0201
United States of America
declares that the product:
Product Name: 9MBHE (Handheld) &
9MBM

(Machine-Mounted)
Plasma Spray Guns
Product Type: Arc Welding Equipment
conforms to the following applicable Standards:
EN 60204-1 Safety of Machines (Electrical Equipment)
pr EN 1050 Risk Assessment
EN 55 011 Group 1, Class A, Conducted Emissions, 150 kHz to 30 MHz
EN 55 011 Group 1, Class A, Radiated Emissions, 30 MHz to 1 GHz
EN 61000-4-2 Electrostatic Discharge
ENV 50140 Radiated Immunity
ENV 50204 Radiated Immunity, Pulsed
IEC 801-4 EFT/Burst, Power and I/O Leads
EN 61000-4-11 Voltage Dips & Interrupts, Power Leads
Sulzer Metco hereby acknowledges compliance in accordance with the above listed
standards in the design, manufacture and testing of the above listed equipment.
Director of Equipment Operations
Westbury, New York
January, 1998
9MB
Plasma Spray Guns
TABLE OF CONTENTS
Section Title
Safety Measures
1 Description
2 Equipment Required
3 Optional Equipment
4 Installation
5 Operation
6 Maintenance
7 Disassembly and Assembly
8 Recommended Spare Parts
9 Replacement Parts
Spraying Tables
Doc. 56348, Issue b
PS Safety Measures
English (US)
Safety Measures
For Plasma Equipment
NOTICE
It is imperative that all personnel responsible for
the installation, operation and maintenance of
this equipment read and understand the entire
Safety Measures section of this instruction
manual prior to working on or using the
equipment.
The operator of this equipment must be aware of
all safety precautions and procedures related to
the 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 to
the presence of important operating instructions, safety
considerations, and special instructions. These symbols (along
with their definitions) are shown below.
Additional information of general importance is
provided.
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 from
moving parts.
GENERAL
Spraying can be a completely safe process when performed by an
operator who follows the recommended precautionary measures,
exercises care in operation, has a proper understanding of
spraying practices, and possesses a knowledge of the equipment.
However, spraying can be hazardous, because it requires the use
of combustible gases, hoses under high pressure, potentially
irritating or toxic spray materials, noise, heat, and UV radiation.
It may involve air contaminated by dust, fumes and mists. It is
advisable to remove the operator from the process.
Consult the Sulzer Metco Instruction Manual, Material Safety
Data Sheet (supplied with materials), and applicable national and
local jurisdiction safety and health regulations before using spray
materials. Some individuals may show unusual sensitivity to
exposure to these materials. Failure to observe proper practices
may result in health hazards.
When safety becomes a habit, the equipment can be used with
confidence.
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 with
Sulzer Metco spraying equipment:
Read, understand, and follow the safety and operation
instructions provided in the instruction manuals.
Never operate equipment if floor of spraying area is wet.
Do not operate equipment above recommended pressures and
flows.
Sulzer Metco thermal spray equipment has been expressly
designed 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 surfaces
and objects. Sprayed metal and surfaces are hot.
Sulzer Metco spray equipment is designed to use only Sulzer
Metco spare parts. The use of other than Sulzer Metco parts may
pose a safety hazard, and will void the warranty.
Equipment Handling
Maintain the equipment in first class condition. Follow the
maintenance recommendations in the Sulzer Metco instruction
manuals.
Remember that the stream of sprayed metal is hot. Point the gun
away from yourself and away from materials that will burn.
Carelessness in pointing the gun at paper, wood, or oily rags can
result in fire.
Be especially careful not to spray on the hoses, when operating
the gun. Hoses will burn. Keep them out of the way. All
compressors, regulators, etc., should be inspected regularly for
leaks and loose connections.
REDUCTION OF FIRE AND EXPLOSION HAZARDS
Gases
Fuel gases are highly dangerous. They can asphyxiate, combust
or explode.
Follow the safety measures outlined below, when working with
fuel gases:
All gas equipment such as fuel gas lines, air lines, compressors,
and regulators, should be inspected regularly for leaks and loose
connections.
Maintain proper ventilation where compressed gases are in use.
Route hoses to prevent strain, damage, or contact with oils or
grease.
GAS CYLINDER PRECAUTIONS
The storage, handling, and use of fuel gas cylinders, should be in
accordance with national and local regulations. In addition, the
safety measures outlined below should be followed:
Charged gas cylinders are potentially dangerous. Never put a
gas 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 connected
for use.
Do not hang a spray gun or hoses on regulators or cylinder
valves, because a fire or explosion may result.
Do not set gas cylinder regulators above pressure settings
recommended by material spray tables in the Sulzer Metco
instruction 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 the
following safety considerations:
Aluminum and magnesium dust are particularly hazardous.
Exercise extreme care in handling them.
To minimize the danger of dust explosion resulting from
spraying, adequate ventilation must be provided for spray
booths, and other confined spaces, to prevent the accumulation
of fumes and dust.
Inspect and clean regularly to ensure that there is no potentially
dangerous accumulation of dust. Good housekeeping in the
work area is essential.
All closed collectors should be provided with blowout holes or
relief panels. All fans, pipes, dust arrestors, and motors should
be external to the duct system.
Before cleaning booths, pipes, etc., purge area of any hazardous
fumes using the ventilating exhaust system. Ensure that
ventilating exhaust system is off while working on it and that an
alternate 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 repair
operations.
When cleaning, all sources of ignition in the area around the
collector should be eliminated.
When making repairs on the ventilating or dust collecting
equipment, no welding or cutting should be done before the
equipment is washed down and all metal dust removed.
VENTILATION AND EXHAUST SYSTEMS
A suitable spray booth and an adequate exhaust system are
required to avoid the toxic or noxious effects of dust, fumes and
mists, 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 the
gun at the booth opening, the exhaust system must be able to
exhaust 300 CFM (9 cubic meters/min) of air for every square
foot of booth opening. If the booth has an opening of four square
feet (.37 square meters), a system that will exhaust 4 x 300 or
1200 CFM (33 cubic meters/min) should be provided.
When a console is located outside of the spray booth, the gas
cabinet ventilation (located on top of the unit) must be ducted into
the spray booth enclosure. In addition, the console has a separate
interlock that should be connected to an exhaust outlet sensor
(customer supplied). The interlock will prevent the plasma
system from operating, when the exhaust system is not in
operation.
If there is any question as to the effectiveness of the ventilation
and exhaust system or as to the presence of airborne particles that
the operator might inhale, consult a competent industrial
hygienist.
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 Safety
Data Sheet. Never spray a material without reading and following
the precautions contained in the Material Safety Data Sheet.
Some materials (beryllium, tellurium and their oxides, for
example) are very dangerous to the respiratory system and should
not be used at all, except under the supervision of a competent
industrial safety engineer.
Blasting, spraying, and finishing all produce dust. Blasting,
spraying, and finishing should be considered as hazardous as
spraying such materials.
The following materials are specifically listed because they are
commonly sprayed. There are many other hazardous materials
that are not listed because they are not commonly sprayed.
Because standards change and new information becomes
available from time to time, it is strongly recommended that the
information contained in the Material Safety Data Sheet, which
comes with the material being used, be consulted.
Complete and current information should be obtained from
national and local regulations.
Lead, Lead Alloys, Cadmium and Chromium
The fumes of lead, lead alloys (such as solder and lead base
babbits), cadmium alloys, and chromium alloys are extremely
hazardous. Consult an industrial hygienist for the proper
protection.
Zinc, Zinc Alloys, (Zinc, Bronzes and Brasses)
Fumes of these metals are toxic. Consult an industrial hygienist
for the proper protection.
Nickel and Nickel Components
Fumes of nickel components are potentially hazardous. Consult
an industrial hygienist for the proper protection. One known
highly toxic compound is nickel carbonyl. Under certain
conditions, nickel carbonyl can be formed by the combination of
nickel and carbon monoxide.
Ozone and Nitric Oxides
The plasma produces small traces of ozone and nitric oxide that
become toxic in high concentrations. Exhaust equipment, suitably
sized to remove spray dust, will also lower ozone and nitric oxide
concentrations well below permissible limits for continuous
personnel exposure in the spray area. Exhaust equipment
inadequately sized for complete dust removal may permit toxic
concentrations of ozone or nitric oxide to accumulate.
PERSONAL PROTECTION
Reduction Of Respiratory Hazards
Consult the Sulzer Metco Instruction Manual, Material Safety
Data Sheet, and applicable national and local jurisdiction safety
and health regulations (or local standards), before using spray
materials.
During the spray process, a respirator approved by applicable
national and local regulations should be worn at all times, to
protect the operator from exposure to dust and fumes. Respirators
should 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 other
unknown causes of health impairment due to contact with the
body cannot usually be predicted. To avoid such reaction, never
allow spray dust to enter eyes, mouth, cuts, scratches, or open
wounds. After spraying, and especially before eating or handling
food, wash hands thoroughly. Wear fireproof or flame resistant
protective clothing.
The particles in the plasma spray stream strike the workpiece at
high velocity, resulting in rebound of sprayed particles. The
workpiece should be placed far enough inside the spray booth to
minimize the amount of particles rebounding out of the booth.
Rebound from inside surfaces of the booth itself is usually not a
problem. Where the work cannot be adequately enclosed, higher
air velocities may be required.
Any finely divided material may damage the respiratory system
in varying degrees. Whenever fume concentration is high enough
to cause operator discomfort (dizziness, nausea, etc.), stop
spraying. Check the ventilating and exhaust systems and related
equipment. If this equipment is not adequate and not operating
properly, respirator equipment must be provided. If operator
discomfort continues, even with the added protection, stop
spraying and recheck all equipment. Do not resume spraying
until all possibilities of discomfort have been eliminated.
In areas distant from spraying, where no respiratory protection
seems needed, periodic air sampling is recommended.
Air samples should also be taken in the spray area after spraying
has been stopped. Respiratory protection is not required when
spraying is stopped and area is known to be free of harmful dust
and fumes.
Reduction Of Noise Hazards
The operator and other personnel close to the spray operation
must be protected from excessive noise. If possible, the spray
operation should be in an approved spray cabinet. Hearing
protection (that meets local standards) should be used. Do not
rely on wads of cotton for hearing protection. They are
ineffective against high-intensity noise.
Noise levels at any location depend on such factors as equipment
operating parameters; background noise; room size; and wall,
floor, and ceiling materials. To determine the exact noise level, it
is necessary to measure the sound level. The various spray guns
can 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 avoid
electrical hazards.
If a line cord with a ground lead is provided with the equipment
for connection to a switchbox, connect the ground lead to the
grounded switchbox. If a cable plug is added for connection to a
grounded mating receptacle, the ground lead must be connected
to a safety ground. If the line cord comes with a three pole plug,
connect to a grounded mating receptacle. Never remove the
ground 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 damaged
insulation 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 hot
metal and sparks. Do not walk on or drive vehicles over cables.
Terminals, wire raceways, and other exposed parts of electrical
units should have insulating covers secured before operation.
EQUIPMENT
MAXIMUM
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 not
be disconnected or shunted out.
Before installation, inspection, or service of equipment, shut off
all power and remove line fuse (or ensure power switch is locked
or 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 shock
burns or flash switch arcing.
Before leaving equipment unattended, always shut off and
disconnect all power from equipment.
A power disconnect switch must be available near the power
source as required by code.
Protection For Wearers of Electronic Life Support Devices
(Pacemakers)
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 HAZARD
The plasma spray stream emits ultraviolet radiation at a level that
can cause severe sunburn to skin and eyes. Hands, body and face,
including eyes, must be protected when operating the gun. People
in the vicinity watching the operator, or working in the area and
exposed 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 protection
of face, hands and eyes.
Radioactive Powders
Aside from ultraviolet, the plasma gun produces no other
radiation such as X-rays, gamma rays or beta rays. However,
radiation of this type can occur when spraying radioactive
powders. Whenever radioactive powders are sprayed, full
precautions must be taken to protect all personnel. Work
involving radioactive materials should always be done under the
supervision of an expert in the field of radiation safety and in
accordance with recommendations of national nuclear regulatory
agencies.
FLUOROCARBON MATERIAL (O-RINGS)
PRECAUTIONS
Sulzer Metco specifies the use of O-rings made of fluorocarbon
synthetic rubber, for use in most Sulzer Metco equipment. This
material provides a wide range of desirable properties, including
high flame and heat resistance, resistance to compression-set, and
broad chemical compatibility.
At elevated temperatures above 316 degrees C (600 degrees F),
fluorocarbon material may degrade, emitting hydrogen fluoride
fumes that, in the presence of water, may react to form highly
corrosive hydrofluoric acid. This can cause severe burns on bare
skin with delayed symptoms.
In normal operation of Sulzer Metco gas guns, gun O-ring
temperatures 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 or
gummy and sticky. To avoid corrosive skin burns, observe the
precautions 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. Fluorocarbon
rubber manufactures advise further neutralizing the part with
lime-water (calcium hydroxide solution).
3. Discard the gloves when finished.
First Aid
If heat-degraded fluorocarbon rubber contacts bare skin, do the
following immediately:
1. Wash skin thoroughly with soap and water.
2. Rub a 2.5% calcium gluconate gel into the skin until any
existing irritation disappears. If irritation persists, consult a
physician.
DISPOSAL OF MATERIALS AND EQUIPMENT
Disposal of all equipment material and collected overspray shall
be in accordance with local regulations.
Some materials may be classified as hazardous. Follow local
requirements and information on Material Safety Data Sheet.
Some guns may contain a small amount of oil. Drain oil and
dispose of per local regulations.
1-1
SECTION 1
DESCRIPTION
Table of Contents
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Modular Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Primary Gas Settings and Insulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Nozzles and Powder Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Dual Powder Port Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Front Gun Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Gun Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Powder Feed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Emergency OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Packaged Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
9MBH Handheld Plasma Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
9MBHE Handheld Plasma Spray Gun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
9MBM Machine-Mounted Plasma Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
FEATURES
Sulzer Metcos 9MB plasma spray guns are engineered for reliable performance. They produce
high-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, a
machine-mounted plasma spray gun with an appropriate base-and-extension setup can apply
coatings 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 the
gun are supplied with an argon front insulator (two gas holes) installed. A nitrogen front insulator
is also furnished (not installed). Both insulators can be used for power levels up to 80 kVA. An
optional argon front insulator (six gas holes) is also available, providing optimum performance at
power levels between 55 kVA and 80 kVA.
1-3
1-4
1-2
Nozzles and Powder Ports
Various nozzles and powder ports can be installed on 9MB plasma spray guns to accommodate a
wide range of spray parameters. One-piece and two-piece nozzles are available. Both kinds of
nozzles 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 repetitive
basis, dual powder port hardware is provided. With dual powder port hardware installed, the
problem of one powder contaminating the feed line or discharge hardware of the other is
eliminated.
Front Gun Section
The front gun section is made up of a gun nozzle, a water channeling head and an electrode and
insulator assembly. These components contain passageways for circulating cooling water to the
nozzle and electrode.
Gun Handle
The gun handle contains a powder feed switch for starting and stopping the flow of powder. It also
contains an emergency OFF switch to stop system operations. In the 9MBH plasma spray gun, an
18-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 is
27 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-style
double-action push button. When the gun is properly set up, pressing the switch will initiate
powder 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 other
emergency stop controls in the plasma control unit and in other equipment. After the emergency
OFF switch has been pressed, the system must be restarted at the plasma control unit before the
gun can be operated again.
1-3
PACKAGED VARIATIONS
Sulzer Metcos 9MB plasma spray guns are available in three packaged variations: the 9MBH, the
9MBHE, and the 9MBM.
9MBH Handheld Plasma Spray Gun
The 9MBH handheld gun has a gun handle equipped with a support bracket for suspending the
gun. It is suitable for use with Sulzer Metco 9MC, 7MC, or LCP plasma control units. The
following are also included with this gun package:
Cat. No. Description Quantity
9MB888 Instruction Manual for 9MB Plasma Spay Guns 1
7M195 Gun Control Cable, 18 feet (5.5 m) long 1
9MB961 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 the
gun. It is suitable for use with Sulzer Metco 9MCE or LCPE plasma control units, which conform
to 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 that
the 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 plasma
control units, or as part of a Sulzer Metco MultiCoat
or UniCoat
system. It is especially well

suited for integration into robotic systems.
Cat. No. Description Quantity
9MB888 Instruction Manual for 9MB Plasma Spay Guns 1
56255 Gun Control Cable, 27 feet (8.2 m) long 1
9MB961 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Plasma Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Distribution Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Power Suply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cooling Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Powder feed Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hose and Cable Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
MS Flame Spray Safety Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Required Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cooling Water Purity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cooling Water Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
DC Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
SYSTEM COMPONENTS
Sulzer Metcos 9MB plasma spray guns require ancillary equipment to supply and control plasma
gases, electric power, cooling water and powder. Typically, a complete plasma spray system
includes 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 plasma
spraying operations:
MS Flame Spray Safety Unit
NOTE
For optional equipment and other system
enhancements, refer to the Optional Equipment
section of this manual.
For a description of Sulzer Metco MultiCoat
or
UniCoat
system components, refer to the

appropriate manual.
The following is a brief description of some of these system components. For a more detailed
discussion of the equipment, refer to the applicable instruction manual.
Plasma Control Unit
The 9MC, 9MCE, ValuPlaz
TM
LCP, or ValuPlaz
TM
LCPE Plasma Control Unit contains all
control modules necessary to start and stop the operation of a plasma spray gun and other system
components.
The control unit supplies and continually meters and maintains preset gas flows to the gun, as well
as DC electric power and cooling water used by the gun. It monitors and controls spraying
parameters and sequences system operation, thus permitting repeatable coating results with
minimal part rejections. The control unit shuts down the gun automatically in the event that any
pressures go below safe operating levels.
Distribution Unit
The 9MCD, LCPD, LCPDE, or JAM-1010 Distribution Unit is a box which receives DC electric
power from the systems power supply unit, and cooling water from the heat exchanger, and sends
both 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 an
electric 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 Supply
Unit contains rectifiers that convert three-phase plant AC power to the DC power used by the
plasma 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 on
the material (powder) being sprayed. Refer to the Spraying Tables section of this instruction
manual, 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 supply
of 80 V at 1100 A, in continuous operation mode (100 % duty cycle).
CAUTION
When using a power supply unit whose rated DC
output is higher than the 9MB gun maximum power
supply rating, set the DC voltage and amperage
within these limits before starting the system, to avoid
overloading the gun. The Spaying Tables in this
manual provide recommended settings for the
material being sprayed.
Cooling Unit
The HE-300, 8ME, 9MK, or FC250 cooling unit circulates deionized cooling water through the
plasma control unit and the plasma spray gun at a sufficient pressure and flow rate to keep the
internal parts of the gun from overheating.
Depending on the quality and temperature of the plant water supply, the cooling unit may be a
water-to-water heat exchanger (HE-300, 8ME) or a refrigerated (water-to-refrigerant) heat
exchanger (9MK, FC250). If plant water supplied to the system exceeds 65 F (19 C), install a
refrigerated heat exchanger.
Powder Feed Unit
The 9MP, 9MPE, 9MP-CL, or 9MPE-CL powder feed unit supplies metered quantities of powder
to 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 hose
carrying 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 braided
hose carrying cooling water)
One plasma gas hose assembly (Cat. No. 7MH110). This hose is 30 feet (9.1 m) long.
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, ultraviolet
radiation, 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 Control
9MP-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 electrical
power, 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 spray
system 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 a
closed-loop heat exchanger system is recommended to cool the gun. Minerals such as calcium and
magnesium 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, expressed
in parts per million (PPM). An unacceptable level of scale forms in the equipment cooling water
passages 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 of
these thinner annular passages, scale will form at a faster rate in TAP cooled nozzles than in
conventional one-piece nozzles. One-piece nozzles are likely to have a longer service life in a hard
water environment.
If the cooling water is deionized and circulated in an appropriate heat exchanger, two-piece TAP
cooled nozzles will receive more efficient cooling and will tend to have a longer service life than
conventional 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 power
supply. (Refer to Sulzer Metco Power Supply Units table in this section for a list of non-CE and
CE equipment available.)
WARNING
USE OF A POWER SUPPLY NOT SPECIFICALLY
DESIGNED TO OPERATE A SULZER METCO
PLASMA GUN CAN RESULT IN DAMAGE TO
THE GUN AND PERSONAL INJURY.
3-1
SECTION 3
OPTIONAL EQUIPMENT
Table of Contents
Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
7MT-2' Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
7MST-2' Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Machine Mounts and Cable Connectors for Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Machine Mount for 7MT Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Machine Mount for 7MST Extensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Right-Angle Cable Connector Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Nozzles, Powder Ports, and Powder Port Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Nozzles and Powder Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Swivel Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Quad Powder Port Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Hoses and Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
7MH-25 Hose and Cable Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Gun Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Workpiece Cooling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Quad Powder Port Air Jet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Special Gun Mounting and Suspension Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Mounting Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Mounting Adapter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Tool Post Bracket Assembly and Tool Post Fixture Assembly . . . . . . . . . . . . . . . . . . . . . 3-4
Hook and Mounting Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Gun Suspension Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cable Support Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cable Support Strap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Right-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 as
small as 2 inches (50 mm) in diameter, to a depth of about 18 inches (455 mm). This accessory can
be 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 the
inside 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 be
assembled with a machine-mount base (9MBM with front gun section removed) and connected to
form 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 a
7MT-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 a
7MST-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 a
headstock, space may be limited. Travel of handling equipment may be impaired, or straight-out
cable 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 to
the axis of the gun. This package includes elbows and other parts required for safe and efficient
right-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 a
complete list of nozzles and powder ports suitable for 9MB plasma spray guns, refer to the
Replacement Parts section of this instruction manual, and to the Spraying Tables for hardware
setup requirements.
Cat. No. 9MB963 Swivel Connector
This 45 stem and swivel connector assembly does not connect the powder hose onto the powder
port stem (Cat. No. 3M202). Instead, it screws directly into the mounting block, seating against the
powder port. As a result, powder feed hoses have a lower profile above the 9MB plasma spray
gun. 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, it
allows 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-port
powder discharge operation with workpiece cooling capability. It includes an air jet head and
powder port clamp, two adjustable air cooling nozzles, connecting air hoses, hardware, and
instructions.
SPECIAL GUN MOUNTING AND SUSPENSION HARDWARE
The following optional hardware is designed to increase the versatility of both hand-held and
machine-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 the
axis 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 9MBM
plasma spray gun machine-mount base, allows for more flexible positioning of the gun. A 360
rotation of the gun is made possible with this setup.
3-4
Cat. No. 7M90 Tool Post Bracket Assembly and
Cat. No. 6P125 Tool Post Fixture Assembly
These accessories allow for machine-mount setups of the 9MBH and 9MBHE handheld plasma
spray 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 eye
support bracket. The Tool Post Bracket Stud (Reference 14945) fits into a hole in the Tool Post
Cross Bar (Reference 1675) of the tool post fixture assembly, which in turn attaches to the tool
post 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 an
insulated 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 spray
gun. It includes a spring-loaded, extendible cable which hooks into the eye of the support bracket
at the top of the gun. The gun hangs from the cable, directly in front of the spray booth. The
package 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 base
assembly (Cat. No. 9MB165) or with a gun machine mount for a 7MT or 7MST extension, in
setups 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 base
assembly (Cat. No. 9MB165) or with a gun machine mount for a 7MT or 7MST extension, in
setups where the water-cooled cables and the plasma hose are connected at a right angle to the axis
of the gun.
4-1
SECTION 4
INSTALLATION
Table of Contents
System Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Hose and Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
9MBH or 9MBHE Handheld Plasma Spray Gun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
9MBM Machine-Mounted Plasma Spray Gun with Cable Support Strap. . . . . . . . . . . . . 4-6
9MBM Machine-Mounted Plasma Spray Gun with Voltage Divider . . . . . . . . . . . . . . . . 4-8
SYSTEM HOOKUP
Installation of Sulzer Metcos 9MB plasma spray guns involves connecting hoses and cables
between the gun and a control unit, and between the gun and a powder feed unit.
WARNING
BECAUSE OF HIGH VOLTAGES PRESENT IN
THE SYSTEM, ALL INSTALLATION WORK
MUST BE DONE BY QUALIFIED SULZER
METCO FIELD SERVICE PERSONNEL.
All variations of the 9MB plasma spray gun, the 9MBH and 9MBHE handheld guns and the
9MBM 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 hose
between the gun and the plasma control unit. The water-cooled electric cables and the plasma gas
hose are supplied in the following packages:
7MH Hose and Cable Unit, including two cables 15 feet (4.5 m) long and one plasma gas
hose 19 feet (5.8 m) long
7MH-25 Hose and Cable Unit, including two cables 25 feet (7.6 m) long and one plasma
gas hose 30 feet (9.1 m) long (optional)
In addition, one or more powder feed hoses must be connected between the gun and the powder
feed 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 connected
between the gun and the control unit. An 18-foot (5.5 m) long gun control cable is supplied with
the 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 the
plasma control unit, refer to the control units instruction
manual.
To complete the powder feed hose connections to the
powder feed unit, refer to the powder feed units
instruction manual.
GROUNDING
Check the plasma spray system for proper DC grounding. The DC+ circuit must be grounded in
only one place.
CAUTION
Grounding the DC+ circuit in more than one place
will cause errors in current readings and can also
damage the equipment.
NOTE
It is generally best to ground the DC+ output terminal at
the power supply unit. Sulzer Metco LCPR and 9MRB
power supply units have an internal chassis ground
connection for their positive (+) DC output terminals.
If such grounding connection is not provided (as in the
9MR and 9MRU power supply units), it is recommended
to install a #8 AWG (3.7 mm OD) ground wire between
the DC+ output terminal and the chassis of the power
supply unit.
Using an ohmmeter, check for a good ground between the DC+ output terminal in the power
supply unit and the AC input ground terminal.
4-3
WARNING
THE 9MBM MACHINE-MOUNTED PLASMA
SPRAY GUN MUST BE ISOLATED FROM THE
GUN MANIPULATOR TO PROTECT AGAINST
ELECTRICAL SHOCK HAZARD.
HOSE AND CABLE CONNECTIONS
WARNING
BEFORE PERFORMING ANY INSTALLATION
WORK, DISCONNECT ALL ELECTRICAL
POWER 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 section
of this manual.)
2. Connect either end of one powder feed hose (one hose supplied with each powder feed
hopper) to the powder port stem in the powder port hardware. For dual powder feeds, connect
the second powder feed hose in the same way to the second powder port stem in the dual
powder port hardware supplied with all 9MB plasma spray guns (see Figure 4.1). For
quadruple powder port feeds, connect the third and fourth powder feed hoses to the third and
fourth powder port stems in the quad powder port hardware (optional Quad Powder Port
Clamp, 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 gun
handle to expose the cable fittings and the markings on the posts.
NOTE
See Figure 4.1. The forward post is marked NOZ+ and
has 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), slide
one of the insulators, smooth narrow bore end first, over one end of the cable, far enough to
expose 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 gun
post 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), slide
the remaining insulator, smooth narrow bore end first, over one end of the cable, far enough to
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 gun
post 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 TO
PROTECT AGAINST ELECTRIC SHOCK
HAZARD.
CAUTION
Keep the water-cooled cables out of puddles and
separated from each other to prevent leakage of
high-frequency voltage and possible faulty ignition.
10. See Figure 4.1. Remove the thread protector from the free end of the front gun body hose
assembly (plasma gas pigtail) at the bottom of the gun handle. Using the end of the plasma
gas hose with the smaller fitting nut, connect this fitting nut to the hose fitting on the plasma
gas pigtail. Tighten using two wrenches, one on the hose fitting and one on the pigtail
fitting.
CAUTION
Before connecting the gun end of the plasma gas hose
to the gun, make sure that the front gun body hose
assembly (plasma gas pigtail) is tightly connected to
the 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 switch
assembly (electrical pigtail) at the bottom of the gun handle. Connect the female connector
on 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 FEED
HOSES

NOZZLE (NOZ+)
WATER-COOLED
ELECTRICAL CABLE
HERE
INSULATOR
AND CONNECT
REMOVE
REMOVE
INSULATOR
AND CONNECT
ELECTRODE (EL-)
WATER-COOLED
ELECTRICAL CABLE
HERE
PLASMA GAS
PIGTAIL ELECTRICAL
PIGTAIL
REMOVE THREAD
PROTECTOR AND
CONNECT PLASMA

REMOVE THREAD
PROTECTOR AND
CONNECT GUN
CONTROL 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:
of this manual.)
a current connection insulator (Cat. No. 7M144) over one end of the cable, far enough to
4. Insert the end of the nozzle cable with the insulator through the lower hole in the cable support
strap (see Figure 4.2).
post fitting.
6. Using the electrode water-cooled electric cable (with fittings marked EL- at each end), slide
a 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 cable
support strap (see Figure 4.2).
post fitting.
9. Slide both current connection insulators over the cable fittings and over the gun fittings, so that
no part of the connecting fittings is exposed.
WARNING
CURRENT CONNECTION INSULATORS MUST
BE IN PLACE TO PROTECT AGAINST
4-7
CAUTION
Keep the water-cooled cables out of puddles and
separated from each other to prevent leakage of
high-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 the
plasma gas hose fitting on the gun (see Figure 4.2). Tighten using two wrenches, one on the
hose fitting and one on the gun fitting.
Figure 4.2 9MBM Machine-Mounted Plasma Spray Gun
Installation with Cable Support Strap
9MBM Machine-Mounted Plasma Spray Gun with Voltage Divider
NOTE
The Voltage Divider (Cat. No. 9MCD600) is supplied
only with a Sulzer Metco 9MCD Distribution Unit. See
9MC Plasma Control Unit instruction manual for
description and replacement parts.
NOZZLE (NOZ+) WATER-COOLED
ELECTRIC CABLE
(INSULATOR IN PLACE)
ELECTRODE (EL-) WATER-COOLED
ELECTRIC CABLE
CABLE SUPPORT
STRAP
PLASMA GAS HOSE
4-8
To connect the required hoses and cables to a 9MBM machine-mounted gun with a voltage
divider, proceed as follows:
of this manual.)
a current connection insulator (Cat. No. 7M144) over one end of the cable far enough to
post fitting.
5. Slide the current connection insulator over the connected cable and gun fittings, so that no part
of the connecting fittings is exposed.
WARNING
THE CURRENT CONNECTION INSULATOR
MUST BE IN PLACE TO PROTECT AGAINST
6. Dismantle the voltage divider, maintaining the orientation of each part. Unscrew the flared
clamp nut from the housing, exposing the split ring. Pull out the split ring, leaving the O-ring
in place. Using the electrode water-cooled electric cable (with fittings marked EL- at each
end), slide the clamp nut, flared end first, then the split ring with O-ring in place, then the
housing of the voltage divider over one end of the cable, far enough to expose the fitting nut.
post fitting.
8. Slide the voltage divider housing over the connected fittings. Insert the front shoulder end of
the housing into the locking ring (Cat. No. 9MB142) in the rear of the 9MBM gun
machine-mount base assembly, using a pushing and twisting motion.
NOTE
Position the voltage divider housing so that the red
positive 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 gun
machine-mount base assembly, push the split ring into the rear fitting end of the housing as far
as it will go.
10. Screw the clamp nut on the external thread of the split ring, then on the external thread of the
fitting 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, nearest
the red positive gun reference lead (marked +), and replace it with the gun terminal adapter
screw (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 gun
terminal adapter screw, and screw it in part way. Position the wire terminal of the positive gun
reference lead between the terminal screw and the gun terminal adapter screw, then secure the
connection 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 the
plasma gas hose fitting on the gun (see Figure 4.3). Tighten using two wrenches, one on the
hose fitting and one on the gun fitting.
Figure 4.3 9MBM Machine-Mounted Plasma Spray Gun
Installation with Voltage Divider

TERMINAL ADAPTER
SCREW
POSITIVE GUN REFERENCE
LEAD (MARKED +)
TERMINAL SCREW
VOLTAGE
DIVIDER
NOZZLE (NOZ+)
WATER-COOLED
ELECTRIC CABLE
PLASMA GAS HOSE
ELECTRODE (EL-)
WATER-COOLED
ELECTRIC CABLE
5-1
SECTION 5
OPERATION
Table of Contents
Gun Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
System Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
9MB and 9MBH Handheld Plasma Spray Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Operating the Powder Feed ON-OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Operating the Emergency OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
9MBM Machine-Mounted Plasma Spray Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
System Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
GUN CONTROL
Except for the gun handle control switches in the 9MBH or 9MBHE handheld variations, the
operation 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 the
applicable plasma control unit instruction manual.
WARNING
BEFORE OPERATING THE EQUIPMENT, THE
OPERATOR MUST BE THOROUGHLY
FAMILIAR WITH THE SAFETY MEASURES
OUTLINED AT THE FRONT OF THIS MANUAL.
CAUTION
Before starting operation, be sure that all
hardware installed in the gun (nozzle, powder
ports, front insulator) is correct for the powder to
be sprayed and the primary plasma gas to be
used. The use of improper gun hardware can
result in poor gun operation, and can adversely
affect 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 flow
through 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 stops
the powder flow. Ignition and other functions are
controlled from the plasma control unit. Refer to the
appropriate plasma control unit or spray system
instruction 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 OFF
switch. Except for emergency conditions, such as a nozzle water leak or an excessively high
voltage or amperage reading, the emergency OFF switch should not be used to shut down an
operating gun. Follow the normal shutdown procedure as described in the applicable plasma
control unit instruction manual.
5-3
NOTE
Once the emergency OFF switch is activated, the system
must be restarted at the console before the gun can be
operated again. Refer to the appropriate plasma control
unit or spray system instruction manual.
CAUTION
Pressing the emergency OFF switch during a plasma
spraying operation could result in clogged powder
feed 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. All
system 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 procedure
outlined in the applicable plasma control unit instruction manual.
6-1
SECTION 6
MAINTENANCE
Table of Contents
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Avoiding Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
General Gun Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Water-Cooled Electric Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
TROUBLESHOOTING
WARNING
BEFORE PERFORMING ANY ASSEMBLY,
DISASSEMBLY OR ADJUSTMENT OF ANY
PART OF A 9MB GUN INSTALLED IN A PLASMA
SPRAY SYSTEM, DISCONNECT ALL ELECTRIC
POWER FROM THE SYSTEM.
CAUTION
Before starting operation, be sure that all
hardware installed in the gun (nozzle, powder
ports, front insulator) is correct for the powder to
be sprayed and the primary plasma gas to be
used. The use of improper gun hardware can
adversely affect the coating.
The following troubleshooting chart is provided so that, in the event of a gun malfunction, its user
can quickly and accurately isolate and correct the trouble. This chart is intended for qualified
personnel, thoroughly familiar with the safety precautions, system controls, handheld gun controls,
operating procedures and maintenance activities related to Sulzer Metcos 9MB plasma spray
guns.
6-2
In the event that the malfunction cannot be cleared after using the troubleshooting chart, contact
Sulzer Metco Field Service for further assistance.
TROUBLESHOOTING CHART
Trouble Isolation Solution
Gun does not light. Refer to the plasma control units instruction
manual, and use test ignition procedure to
check for a good spark at gun tip.
Check condition of all gun hardware.
Verify that correct front insulator and other
hardware are installed.
Verify that hardware is properly assembled.
Check the points gap, change if necessary
Clean excess deposits on tip of electrode
with abrasive pad (Scotch-Brite)
Change hardware if necessary.
Make sure nozzle and electrode are properly
seated and locked in place.
Gun lights up and
immediately shuts off,
when using nitrogen gas.
Check water channeling head for tight
connection.
Check for eroded hardware and proper gun
assembly.
Check plasma control unit (refer to
appropriate instruction manual.)
Tighten if necessary.
Replace nozzle or electrode if necessary.
Refer to Disassembly and Assembly section
in this manual.
Check safety shut-offs as described in
instruction manual.
Gun lights, but shuts off
when moved.
Check for faulty water-cooled electric
cables.
Check handheld gun emergency OFF switch
and gun control cable.
appropriate instruction manual).
Check if voltage drop across cables is
different when cables are bent.
Replace emergency OFF switch if
necessary. Check continuity of gun control
cable, and change if necessary.
Check safety shut-offs as described in
instruction manual.
Gun sparks when it
touches a grounded
object (gun suspension
hook, tool post mounting
stud, etc.).
Check for a short to ground, from electrode
water-cooled electric cable connection on
gun to ground or to plasma control unit.
Make sure power supply unit is grounded.
See Grounding in Installation section of this
manual.
Gun spurts copper,
damages nozzle.
Check for gun water leaks.
Check for water in plasma gas hose.
appropriate instruction manual).
Check O-rings, nozzle and electrode, and
replace 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, and
replace as needed.
Purge lines and check gases.
Gun goes on and off
continuously, during
ignition, when using
nitrogen gas.
Verify that water channeling head is tight
and properly seated.
Verify that correct hardware is installed and
properly assembled.
Check for faulty insulator.
Tighten channeling head if necessary (refer
to Disassembly and Assembly section in this
manual).
Check manual for correct hardware and
assembly.
Replace insulator if necessary.
6-3
Gun leaks gas. Check plasma gas hose connection to
handheld gun plasma gas pigtail.
Check all O-rings (see Note).
Tighten plasma gas hose connection.
Replace O-rings as needed.
Cracked nitrogen gas
ring (marked N) on front
insulator.
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 coating
on the water-cooled surfaces indicates a high
concentration of oxygen or ions in the water,
which reduces nozzle life.
Check nozzle (TAP cooled): a white-gray
coating on the water-cooled surfaces
indicates a high concentration of minerals in
the water, which reduces nozzle life.
Check water pressure and flow. Water
pressure 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. The
temperature of water circulating through the
gun should be no more that 65 F (19 C).
Observe plasma spray stream. Except when
spraying copper or chromium powders, the
appearance of a green color in the plasma
flame indicate an excessively worn nozzle.
Do not start gun if water droplets can be
observed in nozzle bore. (This will cause
severe nozzle gouging when in operation.)
Drain water in cooling unit and water lines.
Add distilled, deionized water. For 9MK or
8ME unit, insert a fresh water conditioner
chemical element in cooling unit.
Drain water in cooling unit and water lines.
Add distilled, deionized water. For 9MK or
8ME unit, insert a fresh water conditioner
chemical element in cooling unit.
Adjust water pressure and flow rate as
required. (Refer to cooling unit instruction
manual.)
If water exceeds 65 F (19 C), install a
Stop spraying and inspect nozzle. Change
nozzle if necessary.
Poor electrode life. Check electrode periodically.
Check voltage and amperage readings on
plasma control unit. Excessive voltage or
amperage can accelerate electrode wear.
Check water pressure and flow. Water
pressure 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. The
temperature of water circulating through the
gun should be no more that 65 F (19 C).
Observe plasma spray stream. Bright, white
sparks and streamers in the plasma flame
indicate an excessively worn electrode.
Check gas quality. Plasma gases containing
impurities accelerate electrode wear.
If the tip of the electrode has a concave
crater with a diameter of more than 1/8 inch
(3 mm), replace electrode.
Adjust voltage and amperage according to
parameters specified in the Spraying Tables
for the material being sprayed.
Adjust water pressure and flow rate as
required. (Refer to cooling unit instruction
manual.)
If water exceeds 65 F (19 C), install a
Stop spraying and inspect electrode. Change
electrode if necessary.
Use of pre-purified plasma gases improves
electrode life.
High operating voltage. Check plasma gas quality. Moisture in gas
can cause a higher voltage.
Replace with pre-purified plasma gas.
Low operating voltage. Check gun hardware, and for worn nozzle
and electrode.
Check gas supply.
Correct hardware must be installed for
parameters of material being sprayed.
Check gas connections for leaks, and that
proper gas is being used.
Trouble Isolation Solution
6-4
NOTE
When examining O-rings, be sure to inspect the condition
and assembly of Water Channeling Head O-Ring (Cat.
No. 9MB297). This is a cemented O-ring. (Refer to the
Disassembly 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 following
practices 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 not
use 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.
NOTE
In general, when replacing gun parts, the associated
O-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 their
mating 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, certain
practices can prevent premature wear.
1. Do not start the gun if water droplets can be observed in the nozzle bore. Water in the nozzle
bore will cause severe gouging of the nozzle during operation. Using the Purge control on the
plasma control unit, purge gas through the gun to clear out any water after changing the
nozzle. (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 gun
operation.
NOTE
An orientation mark on the nozzle will aid in determining
rotation sequence.
3. Except when spraying powders containing copper or chromium, the appearance of a green
color in the plasma flame may indicate an excessively worn nozzle. Stop spraying and inspect
the nozzle. Replace as required.
Electrodes
1. Periodically examine the condition of the electrode. If the tip of the electrode has a concave
crater 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 eroded
electrode. 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. Water
on 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, they
must be replaced.
Lubrication
1. Always lubricate O-rings and O-ring seats with a light coating of Sulzer Metco Ringlube
Lubricating 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 nozzle
bore encourage rapid deterioration of the nozzle.
6-6
Cleaning
WARNING
TO PREVENT INJURY, SHUT OFF ALL
ELECTRIC POWER TO THE GUN BEFORE
CLEANING THE NOZZLE OR THE POWDER
PORTS.
When spraying continuously for a half hour or more, an accumulation of powder may form on the
nozzle face and at the exit orifice of each powder port. Such accumulations should be removed at
regular intervals, using a clean, dry, lint-free cloth to wipe off the material.
CAUTION
Do not scrape or file off the accumulations, or damage
to the gun may result.
7-1
SECTION 7
DISASSEMBLY AND ASSEMBLY
Table of Contents
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Standard Tools and Shop Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Special Tools and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
9MB Plasma Spray Gun Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Front Gun Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Water Channeling Head Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Water Channeling Head Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Nozzle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Nozzle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Electrode and Insulator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Electrode and Insulator Assembly in Handheld Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Electrode and Insulator Assembly in Machine-Mounted Guns . . . . . . . . . . . . . . . . . . . . . 7-11
Electrode and Insulator Assembly Disassembly and Assembly . . . . . . . . . . . . . . . . . . . 7-13
Electrode replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Gun Handle (Handheld Guns Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Removing Front Gun Section from Gun Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Gun Handle Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Front Gun Body and Front Gun Body Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Rear Gun Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Switch and Cable Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Gun Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Installing Front Gun Section into Assembled Gun Handle . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Installing Front Gun Section into Disassembled Gun Handle . . . . . . . . . . . . . . . . . . . . . . 7-22
Machine-Mount Base (Machine-Mounted Guns Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Locking Ring Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Electrode Holder Clamp and Hose Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Mounting Stud and Hose Fitting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Plasma Gas Hose Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Powder Port Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Installing Dual Powder Port Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Powder Port Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
7-2
TOOLS REQUIRED
The following are required to perform disassembly and assembly of Sulzer Metcos 9MB plasma
spray 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 various
parts and assemblies of the gun. Familiarity with the proper procedures for disassembly and
assembly of the gun will help maximize the guns service life and performance.
WARNING
BEFORE PERFORMING ANY ASSEMBLY,
DISASSEMBLY OR ADJUSTMENT OF ANY
PART OF A 9MB GUN THAT IS INSTALLED IN A
PLASMA SPRAY SYSTEM, DISCONNECT ALL
ELECTRICAL POWER FROM THE SYSTEM.
Quantity Description
2 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. Description
1 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 be
divided into three main sections:
Front gun section
Gun handle or machine-mount base
Powder port hardware
WARNING
DURING DISASSSEMBLY AND ASSEMBLY OF A
SUSPENDED HANDHELD OR AN INSTALLED
MACHINE-MOUNTED PLASMA SPRAY GUN
WITH THE PLASMA GAS HOSE STILL
CONNECTED TO IT, RESIDUAL COOLING
WATER IN THE GUN CAN TRICKLE INTO
EXPOSED PLASMA GAS PASSAGES AND DOWN
THE PLASMA GAS HOSE. WHEN THE GUN IS
LIGHTED AFTER REASSEMBLY, THIS WATER
IS FORCED UP THE PLASMA GAS HOSE INTO
THE GUN, CREATING AN EXPLOSIVE
MIXTURE WHICH WILL DAMAGE THE ENTIRE
FRONT GUN SECTION AND MAY CAUSE
INJURIES.
TO PREVENT THIS, TAKE ONE OF THE
FOLLOWING PRECAUTIONS:
1. DISCONNECT PLASMA GAS HOSE BEFORE
DISASSEMBLY.
2. LIFT AND SUSPEND PLASMA GAS HOSE
ABOVE THE GUN DURING DISASSEMBLY
AND 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 ASSEMBLY
GUN HANDLE
FRONT GUN SECTION
NOZZLE
MACHINE-MOUNT BASE
9MBH AND 9MBHE HANDHELD GUNS
9MBM MACHINE-MOUNTED GUN
7-5
To remove the front gun section, proceed as follows:
3. Remove the water channeling head (refer to Water Channeling Head in this section).
NOTE
When the water channeling head is removed, the nozzle
will come out with it.
4. Remove the electrode and insulator assembly (refer to Electrode and Insulator Assembly in
this section).
To install the front gun section, refer to Gun Handle Assembly (for 9MBH and 9MBHE
handheld guns), or Machine Mount Base (for 9MBM Machine-mounted guns), in this section.
Water Channeling Head (See Figure 7.2)
The Water Channeling Head (Cat. No. 9MB15) is a one-piece assembly that includes a cemented
O-ring.
To remove the water channeling head, unscrew it from the gun front body assembly inside the
gun handle (9MBH and 9MBHE handheld variations), or from the threaded front part of the
machine-mount base (9MBH machine-mounted variation).
To install the water channeling head, screw it onto the gun front body assembly inside the gun
handle (9MBH and 9MBHE handheld variations) or onto the threaded front part of the
machine-mount base (9MBH machine-mounted variation).
NOTE
Before installing the water channeling head, apply a thin
film of Ringlube lubricating compound (Cat. No.
2M182) to the O-ring and the mating threads.
CAUTION
To prevent damage to the threads on the water
channeling head and on the gun front body or
machine-mount base, do not force or cross-thread the
water channeling head when installing it.
Connect the water channeling head hand tight. Do not
use a wrench, or damage to the parts may result.
7-6
Figure 7.2 Nozzle and Water Channeling Head
If the water channeling head binds when installing it onto the front gun body inside the gun
handle (9MBH and 9MBHE handheld variations only), proceed as follows:
1. Remove water channeling head.
2. See Figure 7.7. Loosen the three short and one long gun handle fastening screws (Reference
22489 and Reference 22490, respectively, in 9MBH/9MBHE Hardware Kit, Cat. No. 54128).
3. See Figure 7.4. Loosen the name plate shoulder screw and the name plate mounting screw
(Reference 14928 and Reference 13120, respectively, in 9MBH/9MBHE Hardware Kit, Cat.
No. 54128). Swing the name plate up and out of the way to expose the clamp screw access
hole. Back out the clamp screw (Cat. No. 7M670) until the clamp screw retaining ring touches
the clamp arm. Back the clamp screw an additional 1/4 to 1/2 turn.
CAUTION
To prevent damage to the clamp screw, loosen it only
as much as it takes to free the electrode and insulator
assembly.
4. Make sure that the electrode and insulator assembly (Cat. No. 9MB693 for argon or Cat. No.
9MB694 for nitrogen) is fully seated.
5. Restart installing the water channeling head and screw it on only a few turns.
CAUTION
Do not fully tighten the water channeling head while
the clamp screw is loose.
6. Tighten the clamp screw. Swing the name plate back into position and tighten the name plate
mounting screw and the name plate shoulder screw.
7. Tighten the four gun handle fastening screws.
NOZZLE
NOZZLE NUT
7-7
8. Finish tightening the water channeling head.
CAUTION
Do not overtighten the gun handle fastening screws.
Do not replace water channeling head (Cat. No.
9MB15) with a water channeling head used in a 7MT
or 7MST extension. These parts are not
interchangeable. Installing the wrong water
channeling head could cause damage to the gun.
Water Channeling Head Disassembly
To disassemble the water channeling head, proceed as follows:
1. Remove the nozzle (refer to Nozzle in this section).
2. If channeling head O-ring is damaged, replace it (see Water Channelling Head Assembly in
this section).
CAUTION
Do not mar or damage the contact surfaces when
removing the channeling head O-ring.
Water Channeling Head Assembly
To assemble the water channeling head, proceed as follows:
1. Replace the channeling head O-ring, if necessary (Reference 29520, in 9MBM/9MBH Reseal
Kit, Cat. No. 54127), and cement it into place.
NOTE
Make sure that all contact surfaces are clean and dry, and
use a good quality cement, such as Loctite Depend or
equivalent.
2. Replace the nozzle (refer to Nozzle in this section).
Nozzle (See Figure 7.2)
Nozzle assemblies include one large O-ring and one or two smaller O-rings (one-piece nozzles), or
three smaller O-rings (two-piece nozzles).
7-8
Nozzle Removal
To remove a nozzle from an assembled gun without removing the water channeling head, proceed
as follows:
1. Remove nozzle nut (Cat. No. 9MB8) from the water channeling head.
NOTE
If the nozzle nut is too tightly connected to the water
channeling head to remove by hand, use the nozzle nut
wrench (Cat. No. 55866).
2. Pull the nozzle out of the water channeling head.
NOTE
During nozzle removal, the smaller O-rings remain in
their O-ring bores; however, the large O-ring (Reference
21471 in 9MBM/9MBH Reseal Kit, Cat. No. 54127)
may remain attached inside the water channeling head.
Make sure that the large O-ring comes out with the
nozzle.
Nozzle Installation
To install a nozzle, proceed as follows:
1. Verify that all O-rings are in good condition and lightly coated with Ringlube lubricating
compound (Cat. 2M182).
2. With the large O-ring in place against the shoulder of the nozzle, slide the nozzle squarely,
narrow end first, into the water channeling head, and push it in until firmly seated against the
electrode and insulator assembly.
3. Tighten the nozzle nut onto the water channeling head
NOTE
Hand tightening is usually sufficient. Where a tighter
connection is required, use the nozzle nut wrench (Cat.
No. 55866) to complete the installation.
CAUTION
To prevent damage to the gun, do not overtighten the
nozzle nut.
7-9
Electrode And Insulator Assembly (See Figure 7.3)
The electrode and insulator assembly is made up of the following major parts:
Electrode
Electrode Holder
Front Insulator (Nitrogen or Argon)
Rear Insulator
When a 9MB plasma spray gun is used with nitrogen as the primary plasma gas, a nitrogen front
insulator must be installed in the electrode and insulators assembly. When argon is the primary
plasma gas, the standard (2-hole) argon front insulator (Cat. No. 9MB50) or optional (6-hole)
argon front insulator (Cat. No. 9MB60) must be installed.
NOTE
The nitrogen front insulator is marked N. Both argon
front insulators are marked A.
Figure 7.3 Electrode and Insulator Assembly
Before disassembling the electrode and insulator assembly, it must be removed as a unit from the
gun handle (9MBH or 9MBHE handheld plasma spray gun), or from the front of the
machine-mount base (9MBM machine-mounted plasma spray gun).
There are two different procedures for removal and installation of the electrode and insulators
assembly: one for handheld guns, and for machine-mounted guns.
Electrode and Insulator Assembly in Handheld Guns (See Figure 7.4)
The electrode and insulator assembly is secured to the gun handle (Cat. No. 9MB550 for 9MBH
guns or Cat. No. 56790 for 9MBHE guns) by means of a clamp in the rear gun body (Cat. No.
9MB30). This clamp is tightened or loosened with the clamp screw and retaining ring (Cat. No.
7M670).
ELECTRODE
FRONT INSULATOR
(NITROGEN OR ARGON)
REAR INSULATOR
ELECTRODE HOLDER NUT
ELECTRODE HOLDER
ELECTRODE LOCKING NUT
7-10
To remove the electrode and insulator assembly from a 9MBH or 9MBHE gun handle, proceed
as follows:
1. Remove the water channeling head (refer to Water Channeling Head, previously discussed in
this section).
2. Loosen the clamp screw (Cat. No. 7M670) in the rear gun body. To loosen the clamp screw:
a. Loosen the name plate shoulder screw and the name plate mounting screw (Reference
14928 and Reference 13120, respectively, in 9MBH/9MBHE Hardware Kit, Cat. No.
54128).
CAUTION
Do not remove the name plate shoulder screw
altogether, to avoid losing the spring washer
(Reference 14978 in 9MBH/9MBHE Hardware Kit,
Cat. No. 54128), located under the screw head.
b. Swing the name plate up and out of the way to expose the clamp screw access hole.
c. Back out the clamp screw until the clamp screw retaining ring touches the clamp arm.
d. Back out the clamp screw an additional 1/4 to 1/2 turn.
CAUTION
as much as it takes to free the electrode and insulator
assembly.
3. Carefully pull the electrode and insulator assembly out of the handle.
Figure 7.4 Electrode and Insulator Assembly Removal from Gun Handle
NAME PLATE
MOUNTING SCREW
NAME PLATE
SHOULDER SCREW
NAME PLATE
(IN OPEN POSITION)
CLAMP SCREW
GUN HANDLE
7-11
To install the electrode and insulator assembly into a 9MBH or 9MBHE gun handle, proceed as
follows:
1. Lubricate all O-rings on the electrode and insulator assembly and their mating bores in the gun
handle with a thin coating of Ringlube lubricating compound (Cat. No. 2M182).
2. With the clamp screw loosened in the rear gun body, insert the electrode and insulator
assembly into the gun handle; press on the assembly until the rear insulator (Cat. No.
9MB166) seats firmly.
3. Tighten the clamp screw.
4. Swing the name plate back into position and tighten the name plate mounting screw and the
name plate shoulder screw.
5. Install the water channeling head (refer to Water Channeling Head in this section).
CAUTION
When installing the electrode and insulator assembly
into the gun handle, always tighten the clamp screw
before installing the water channeling head, or
damage to the gun may result.
Electrode and Insulator Assembly in Machine-Mounted Guns (See Figure 7.5)

The electrode and insulator assembly is secured to the machine-mount base (Cat. No. 9MB165) by
means of a clamp and clamp screw device inside the machine-mount base.
To remove the electrode and insulator assembly from the machine-mount base of a 9MBM gun,
proceed as follows:
1. Remove the water channeling head (refer to Water Channeling Head in this section).
2. Remove the plug screw (Reference 15002 in 9MBM Hardware Kit, Cat. No. 54212) on top of
the machine-mount base to provide access to the clamp screw (Reference 14988 in 9MBM
Hardware Kit, Cat. No. 54212).
3. Loosen the clamp screw.
4. Disengage the electrode and insulator assembly from the machine-mount base and carefully
pull it out.
7-12
Figure 7.5 Electrode and Insulator Assembly Removal from Machine-Mount Base
To install the electrode and insulator assembly into the machine-mount base of a 9MBM gun,
proceed as follows:
1. Lubricate all O-rings on the electrode and insulator assembly and their mating bores in the
machine-mount base with a thin coating of Ringlube lubricating compound (Cat. No. 2M182).
2. Loosen the locking ring assembly (Cat. No. 9MB142) in the rear of the machine-mount base
using the locking wrench provided (Cat. No. 9MB98). Back out the knurled locking ring by
unscrewing it one or two turns.
3. Insert the electrode and insulator assembly into the machine-mount base; press on the
assembly until the rear insulator (Cat. No. 9MB166) seats firmly.
4. Install the water channeling head (refer to Water Channeling Head, in this section).
CAUTION
5. Orient the electrode holder clamp and hose fitting (Cat. No. 7M135), by twisting the threaded
end at the rear of the machine-mount base, so that the head of the clamp screw can be seen
facing up through the access hole on top of the machine-mount base.
6. Tighten the clamp screw and replace the plug screw.
PLUG SCREW
LOCKING RING
7-13
CAUTION
Do not allow the clamp screw on the electrode holder
and hose fitting to rotate out of position, or arcover
may result.
The plug screw must be in place before attempting to
light the gun, or arcover may occur. Arcover can
damage the gun.
The plug screw must be clean when replaced. Metal
dust carried into the gun on this screw can cause gun
damage. Do not use metallic screws to replace the
insulating plug screw, or damage to the gun may
result.
7. Tighten the locking ring into the machine-mount base.
Electrode and Insulator Assembly Disassembly and Assembly (See Figure 7.6)
To disassemble the electrode and insulator assembly, proceed as follows:
1. With the electrode and insulator assembly removed, engage the four prongs of the electrode
nut spanner (Cat. No. 10MB104) into the four spanner holes in the face of the electrode
locking nut (Cat. No. 7M14), and loosen the electrode locking nut; remove the electrode
locking nut.
2. Remove electrode (Cat. No. 9MB63 or Cat. No. 9MB64) from the electrode holder.
3. Remove electrode holder nut (Cat. No. 7M17). To remove the electrode holder nut:
a. With one wrench, grip the flats on the electrode holder nut.
b. With a second wrench, grip the flats on the front insulator.
c. Turn the wrenches in opposite directions, to loosen the right-hand thread connection.
d. Unscrew and remove the electrode holder nut.
4. With the electrode holder nut off, the front and rear insulators can be separated and removed
from the electrode holder (Cat. No. 9MB18).
NOTE
Examine all O-rings. Replace using 9MBM/9MBH
Reseal Kit (Cat. No. 54127) and lubricate with a thin film
of Ringlube lubricating compound (Cat. No. 2M182), as
necessary.
7-14
Figure 7.6 Electrode and Insulator Assembly Disassembly and Assembly
To assemble the electrode and insulator assembly, proceed as follows:
1. Assemble the electrode and electrode locking nut into the electrode holder; tighten using the
electrode spanner.
2. Insert the electrode holder into the front insulator, making sure that the two key pins on the
electrode holder fit into the mating slots in the front insulator.
3. Press and twist the rear insulator into the front insulator, until a few threads on the electrode
holder are visible at the rear of the rear insulator.
4. Thread the electrode holder nut into the electrode holder and tighten hand tight.
5. With one wrench gripping the flats on the electrode holder nut, and another wrench gripping
the flats on the front insulator, turn the wrenches in opposite directions, to tighten the
right-hand thread connection.
Electrode Replacement (See Figures 7.3 and 7.6)
To replace electrode (Cat. No. 9MB63 or Cat. No. 9MB64) without removing the front gun
section, proceed as follows:
1. Remove the nozzle nut and the nozzle (refer to Nozzle in this section and see Figure 7.2).
2. Engage the four prongs of the electrode nut spanner (Cat. No. 10MB104) into the four spanner
holes in the face of the electrode locking nut (Cat. No. 7M14), and loosen the electrode
locking nut. Remove the electrode locking nut.
3. Using the electrode puller pliers (Cat. No. 7M108), remove the electrode from the electrode
holder.
4. Inspect the electrode for damage and wear. Replace the electrode if necessary.
5. Insert the electrode into the electrode holder until it seats.
6. Install the electrode locking nut and tighten it using the electrode spanner.
7. Install the nozzle and nozzle nut.
SPANNER HOLE
ELECTRODE LOCKING NUT
KEY PIN
ELECTRODE HOLDER
FRONT INSULATOR *
FLAT
REAR INSULATOR
FLAT
ELECTRODE HOLDER NUT
* Argon front insulator shown.
ELECTRODE
7-15
GUN HANDLE (9MBH and 9MBHE Handheld Guns Only)
Removing Front Gun Section from Gun Handle
To remove the front gun section from the gun handle, proceed as follows:
1. Remove the water channeling head and nozzle (refer to Water Channeling Head in this
section).
2. Remove the electrode and insulators assembly (refer to Electrode and Insulators Assembly in
Handheld Guns, in this section).
Gun Handle Disassembly (See Figure 7.7)
The Handle Assembly (Cat. No. 9MB550 for 9MBH handheld gun or Cat. No. 56790 for 9MBHE
handheld gun) consists of a left half handle and a right half handle. With the gun handle separated
from the front gun section, the disassembly procedure is as follows:
1. Unscrew and remove both insulators (Cat. No. 7M32) from the threaded posts at the bottom of
the gun handle.
2. Remove the four gun handle fastening screws from the left half handle and separate the two
handle halves.
NOTE
There are three short and one long handle fastening
screws on the left half handle (Reference 22489 and
Reference 22490, respectively, in 9MBH/9MBHE
Hardware Kit, Cat. No. 54128).
3. Disassemble the emergency OFF switch from the left half handle by loosening the gun control
switch retaining nut at the base of the switch boot (Cat. No. 3M670). Remove the switch boot
and disengage the switch from the inside of the left half handle.
The right half handle contains the following assemblies:
Description Cat. No. (9MBH) Cat. No. (9MBHE)
Front Gun Body 7M25 7M25
Front Gun Body Hose Assembly 7M58 7M58
Rear Gun Body 7M30 7M30
Switch and Cable Assembly 7M40 56336
7-16
Figure 7.7 (Sheet 1 of 2) 9MBH/9MBHE Gun Handle Construction
Left Half Handle Outside View
Front Gun Body and Front Gun Body Hose Assembly (See Figure 7.7)
The front gun body assembly includes the nozzle water tube and plasma gas tube, which run down
the right half handle to an adapter block, which in turn connects the water tube to the nozzle
water-cooled cable fitting (nozzle gun post). The front gun body hose assembly (plasma gas
pigtail) is joined to the front gun body assembly at the adapter block, in the bottom portion of the
right half handle.
NAME PLATE
GUN CONTROL
SWITCH
RETAINING
NUT
HANDLE
FASTENING
SCREWS
(SHORT)
HANDLE
SCREW
(SHORT)
HANDLE
FASTENING
SCREW
(LONG)
FASTENING
7-17
Figure 7.7 (Sheet 2 of 2) 9MBH/9MBHE Gun Handle Construction
Right Half Handle Inside view (9MBH Shown)
DETAIL
O-RING
HEX NUT
NYLON TIE
FRONT GUN BODY REAR GUN BODY
SWITCH AND
CABLE
ASSEMBLY
ELECTRODE
WATER
TUBE
NOZZLE
WATER
TUBE
PLASMA
GAS HOSE
HEX NUT
(SEE DETAIL)
NOZZLE
WATER-COOLED
CABLE FITTING
(POST)*
ELECTRODE
WATER-COOLED
CABLE FITTING
(POST)*
* INSULATORS

REMOVED
GUN CONTROL
CABLE
(ELECTRICAL
PIGTAIL)
FRONT GUN
BODY HOSE
ASSEMBLY
(PLASMA GAS
ADAPTER
BLOCK
ELECTRODE
HOSE FITTING
CLAMP SCREW
GUN CONTROL
SWITCH
RETAINING
NUT
ORIENT TAB
TO SIDE
PIGTAIL)
7-18
To remove and disassemble the front gun body and the front gun body hose assembly,
proceed as follows:
1. Carefully lift the front gun body (with its connected hose assembly) out of the right half
handle, disengaging the locating pin underneath the front gun body from its mating hole in the
upper portion of the right half handle.
2. Disconnect the front gun body hose assembly from the front gun body by loosening the hex
nut on the plasma gas hose from the adapter block, and removing the plasma gas pigtail.
To assemble and install the front gun body and the front gun body hose assembly, proceed as
follows:
1. Connect the front gun body hose assembly (plasma gas pigtail) to the adapter block by
inserting the threaded tip of the plasma gas hose fitting into the adapter block and tightening
the hex nut on the plasma gas hose until it seats on the adapter block.
NOTE
See Figure 7.7 Detail. Before assembling, clean the
mating threads with solvent, prime with Locquic Primer
Grade T, and apply Loctite Sealant 242, or
equivalent, as a vibration seal for the plasma gas
connection.
An O-ring (Reference 03018 in Reseal Kit, Cat. No.
54127), located in the shoulder recess between the hex
nut and the threaded tip of the plasma gas hose fitting, is
supplied with the front gun body hose assembly. Before
assembling, make sure that the O-ring is in place, not
twisted, and free of nicks and cuts.
2. A nylon tie is used to secure the plasma gas hose onto its fitting. Make sure that the tab on the
nylon tie is oriented to the side of the gun, as shown in Figure 7.7 Detail.
3. Insert the two connected assemblies into the right half handle so that the locating pin on the
front gun body fits snugly into its corresponding hole in the right half handle.
Rear Gun Body (See Figure 7.7)
The rear gun body assembly includes the electrode water tube, which runs down the right half
handle and connects to the electrode water-cooled cable fitting (electrode gun post).
To remove the rear gun body, proceed as follows:
1. Loosen the electrode hose fitting clamp screw (Reference 19525 in 9MBH/9MBHE Hardware
Kit, Cat. No. 54128) that secures the rear gun body assembly to the lower portion of the right
half handle. Remove the screw.
2. Carefully lift the rear gun body out of the right half handle, disengaging the two locating pins
underneath the rear gun body from their corresponding holes in the upper portion of the right
half handle.
7-19
To install the rear gun body, proceed as follows:
1. Carefully place the rear gun body into the right half handle, engaging the two locating pins
into their corresponding holes in the upper portion of the right half handle.
2. Insert the electrode hose fitting clamp screw into the hole in the rear gun body assembly and
the corresponding hole in the lower portion of the right half handle. Tighten the screw to
secure the assembly.
Switch and Cable Assembly (See Figure 7.7)
The switch and cable assembly includes the two gun control switches with their retaining nuts and
ground wire connections. The switches combine to form a short gun control cable known as the
electrical pigtail which extends from the bottom of the gun handle.
To remove the switch and cable assembly, proceed as follows:
1. Disassemble the gun handle (refer to Gun Handle Disassembly in this section).
2. Disassemble the emergency OFF switch from the left half handle by loosening the gun
control switch retaining nut at the base of the switch boot (Cat. No. 3M670). Remove the
switch boot and disengage the switch from the inside of the left half handle.
3. Remove the front gun body and the front gun body hose assembly (refer to Front Gun Body
and Front Gun Body Hose Assembly in this section).
4. Disassemble the powder feed switch from the right half handle by loosening the gun control
switch retaining nut at the base of the switch boot (Cat. No. 3M670). Remove the switch boot
and disengage the switch from the inside of the right half handle.
5. Lift the switch and cable assembly out of the right half handle.
NOTE
To facilitate reassembly, observe the position of each
switch and the placement of its wiring bundle. Observe
how the powder feed switch fits upside down into its
hole in the right half handle, its wiring bundle looping up
and around inside the handle molding. Observe how the
emergency OFF switch fits into its hole in the left half
handle. The wiring bundle for the powder feed switch is
longer than for the emergency OFF switch.
To install the switch and cable assembly, proceed as follows:
1. Install the rear gun body in the right half handle, if it was removed (refer to Rear Gun Body in
this section).
2. Lay the switch and cable assembly into the right half handle, placing the electrical pigtail
inside the strain relief cradle in the gun handle molding, next to the electrode gun post (marked
EL-).
3. Loop the wiring bundle for the powder feed switch up and around inside cavity in the gun
handle molding, and engage the switch through the hole in the right half handle until threads
can be seen on the outside of the gun handle. Position the switch boot over the projecting
threads and screw it into place. Tighten the gun control switch retaining nut at the base of the
7-20
switch boot until it seats against the gun handle.
NOTE
To assure proper operation of the electrical switch, make
sure that 2 1/2 to 4 threads project outside the handle
before fastening with the switch boot.
Before assembly, coat the inside of the switch boot
lightly with talc, using a swab (Q-Tip or equivalent).
4. Install the front gun body and the front gun body hose assembly (refer to Front Gun Body and
Front Gun Body Hose Assembly in this section).
CAUTION
Be careful not to position the electrical pigtail, or
the wiring bundles for the switches, over or under the
front gun body or rear gun body tubes. Otherwise,
misalignment may result when the two handle halves
are assembled, making it difficult to assemble the
water channeling head.
5. Engage the emergency OFF switch through the hole in the left half handle until threads can
be seen on the outside of the gun handle. Position the switch boot over the projecting threads
and screw it into place. Tighten the gun control switch retaining nut at the base of the switch
boot until it seats against the gun handle.
NOTE
To assure proper operation of the electrical switch, make
sure that 2 1/2 to 4 threads project outside the handle
before fastening with the switch boot.
Before assembly, coat the inside of the switch boot
lightly with talc, using a swab (Q-Tip or equivalent).
6. Assemble the gun handle (refer to Gun Handle Assembly in this section).
Gun Handle Assembly
Before a gun handle can be assembled, the front gun body and the rear gun body must be in
alignment. (The Sulzer Metco Handle Assembly, Cat. No. 9MB550 for 9MBH or Cat. No. 56790
for 9MBHE handheld guns, is factory aligned.)
CAUTION
Do not assemble the handle halves until the front gun
body and rear gun body have been aligned.
Misaligned parts in the gun handle can cause
assembly problems when the front gun section is
connected to the gun handle.
7-21
For alignment procedures, refer to Installing Front Gun Section into Disassembled Handle in this
section.
Installing Front Gun Section into Assembled Gun Handle (See Figure 7.4)
To install the front gun section into an aligned handle assembly, proceed as follows:
1. Refer to Electrode and Insulator Assembly in Handheld Guns, in this section. Lubricate all
O-rings on the electrode and insulators assembly and their mating bores in the gun handle with
a thin coating of Ringlube lubricating compound (Cat. No. 2M182).
2. Loosen the name plate shoulder screw and the name plate mounting screw, and swing the
name plate up to expose the clamp screw; loosen the clamp screw. Insert the electrode and
insulator assembly into the gun handle; press on the assembly until the rear insulator seats
firmly.
CAUTION
CAUTION
as much as it takes to insert the electrode and
insulator assembly into the handle.
3. Tighten the clamp screw; swing the name plate back into position and tighten the name plate
mounting screw and the name plate shoulder screw.
CAUTION
4. Install the water channeling head, including the nozzle and nozzle nut (refer to Water
Channeling Head in this section).
CAUTION
Connect the water channeling heat hand tight. Do not
5. Slide insulators (Cat. No. 7M32), internal thread end first, over the nozzle gun post (marked
NOZ+) and the electrode gun post (marked (EL-) at the bottom of the gun handle. Screw
the insulators onto the wider external thread of each post.
7-22
Installing Front Gun Section into Disassembled Gun Handle (See Figure 7.7)
To install the front gun section into a disassembled gun handle, proceed as follows:
1. Install the rear gun body in the right half handle (refer to Rear Gun Body in this section).
2. Install the switch and cable assembly (refer to Switch and Cable Assembly in this section).
Make sure that the electrical pigtail and wiring bundles do not interfere with the proper
alignment of front gun body and rear gun body tubes inside the gun handle.
3. Loop the wiring bundle for the powder feed switch up and around inside cavity in the guns
molded right half handle, and engage the switch through the hole in the right half handle until
threads can be seen on the outside of the gun handle. Position the switch boot over the
projecting threads and screw it into place. Tighten the gun control switch retaining nut at the
base of the switch boot until it seats against the gun handle.
4. Connect the front gun body hose assembly (plasma gas pigtail) to the adapter block on the
front gun body.
5. Insert the two connected assemblies into the right half handle.
6. Lubricate all O-rings on the electrode and insulator assembly and their mating bores in the gun
handle with a thin coating of Ringlube lubricating compound (Cat. No. 2M182).
7. Insert the electrode and insulator assembly through the front gun body and into the rear gun
body. When the front gun body and rear gun body are installed with their locating pins
correctly positioned, the electrode and insulator assembly aligns easily with these parts. Press
on the assembly until the rear insulator seats firmly against the rear gun body.
CAUTION
In order to fully insert the electrode and insulator
assembly into the rear gun body, it may be necessary
to loosen the clamp screw (Cat. No. 7M670). To
prevent damage to the clamp screw, loosen it only as
much as it takes to fully insert the electrode and
insulators assembly.
8. Tighten the electrode hose fitting clamp screw (Cat. No. 7M122) to secure the bottom part of
the rear gun body.
9. Engage the emergency OFF switch through the hole in the left half handle until threads can
be seen on the outside of the gun handle. Position the switch boot over the projecting threads
and screw it into place. Tighten the gun control switch retaining nut at the base of the switch
boot until it seats against the gun handle.
10. Carefully position the left half handle over the right half handle. Insert and tighten the four
gun handle fastening screws.
7-23
11. Loosen the nameplate shoulder screw and the nameplate mounting screw (see Figure 7.4).
Swing the nameplate up to expose the clamp screw (Cat. No. 7M670). With the electrode and
insulator assembly seated firmly in the gun handle, tighten the clamp screw.
CAUTION
12. Swing the nameplate back into position and tighten the nameplate mounting screw and the
nameplate shoulder screw.
CAUTION
13. Install the water channeling head (refer to Water Channeling head in this section).
CAUTION
14. Slide insulators (Cat. No. 7M32), internal thread end first, over the nozzle gun post (marked
NOZ+) and the electrode gun post (marked (EL-) at the bottom of the gun handle. Screw
the insulators onto the wider external thread of each post.
MACHINE-MOUNT BASE (9MBM Machine-Mounted Guns Only)
The machine-mount base (Cat. No. 9MB165) includes the following assemblies:
Locking Ring Assembly (See Figure 7.8)
The locking ring assembly (Cat. No. 9MB142) consists of a knurled brass ring and a plastic
insulator.
Description Cat. No.
Locking Ring Assembly 9MB142
Electrode Holder Clamp and Hose Fitting 7M135
Mounting Stud and Hose Fitting Assembly 9MB335
Plasma Gas Hose Fitting 9MB208
7-24
To remove the locking ring assembly, proceed as follows:
1. Engage the pins in the locking wrench provided (Cat. No. 9MB98) into the corresponding
holes in the locking ring and loosen the assembly from the machine-mount base.
2. Continue to unscrew the locking ring assembly by hand and remove it.
Figure 7.8 Machine-Mount Base Construction
To install the locking ring assembly, proceed as follows:
1. Insert the locking ring assembly, plastic insulator first, over the hose fitting and into the
machine-mount base. Screw the assembly by hand as far as it will go.
2. Engage the pins in the locking wrench into the hole9 in the locking ring and tighten to secure
the assembly.
Electrode Holder Clamp and Hose Fitting (See Figure 7.8)
The electrode holder clamp and hose fitting (Cat. No. 7M135) is an assembly that contains parts
required to secure the front gun section to the machine-mount base, and provides the hose fitting
(marked EL-) for connecting the electrode water-cooled electric cable to the gun.
PLUG SCREW
CLAMP SCREW
LOCKING RING ASSEMBLY
ELECTRODE HOLDER CLAMP
AND HOSE FITTING
PLASMA GAS HOSE FITTING
MOUNTING STUD
AND HOSE FITTING
ASSEMBLY
MOUNTING
PLATE
MACHINE-MOUNT
BASE
CABLE SUPPORT
STRAP ASSEMBLY
(OPTION)
(HANDLE INCLUDED)
7-25
To remove the electrode holder clamp and hose fitting, proceed as follows:
1. Remove the water channeling head from the front of the machine-mount base (refer to Water
Channeling Head, in this section).
NOTE
When the water channeling head is removed, the nozzle
will come out with it.

2. Remove the plug screw (Reference 15002 in 9MBM Hardware Kit, Cat. No. 54212).
3. Remove the electrode and insulator assembly (refer to Electrode and Insulator Assembly in
Machine-Mount Base, in this section).
4. Remove the locking ring assembly (refer to Locking Ring Assembly, in this section).
5. Pull the electrode holder clamp and hose fitting out from the rear of the machine-mount base.
NOTE
The electrode holder clamp and hose fitting contains the
clamp screw (Reference 14988 in 9MBM Hardware Kit,
Cat. No. 54212).
To install the electrode holder clamp and hose fitting, proceed as follows:
1. Insert the electrode holder clamp and hose fitting into the rear of the machine-mount base.
2. Place the locking ring assembly into the machine-mount base, over the electrode holder and
hose fitting, and screw it on by hand a few turns.
3. Install the electrode and insulator assembly (refer to Electrode and Insulator Assembly in
Machine-Mounted Guns, in this section).
4. Install the water channeling head (refer to Water Channeling Head, in this section).
CAUTION
5. Orient the electrode holder clamp and hose fitting, by twisting the threaded end at the rear of
the machine-mount base, so that the head of the clamp screw can be seen facing up through the
access hole on top of the machine-mount base.
7-26
6. Tighten the clamp screw and replace the plug screw.
CAUTION
Do not allow the clamp screw on the electrode holder
and hose fitting to rotate out of position, or arcover
may result.
The plug screw must be in place before attempting to
light the gun, or arcover may occur. Arcover can
damage the gun.
The plug screw must be clean when replaced. Metal
dust carried into the gun on this screw can cause gun
damage. Do not use metallic screws to replace the
insulating plug screw, or damage to the gun may
result.
7. Tighten the locking ring into the machine-mount base.
Mounting Stud and Hose Fitting Assembly (See Figure 7-8)
The mounting stud and hose fitting assembly (Cat. No. 9MB335) includes a mounting plate, into
which are fitted the guns mounting stud and the hose fitting (marked NOZ+) for connecting the
nozzle water-cooled electric cable to the gun. An O-ring (Reference 19716 in 9MBH/9MBM
Reseal Kit, Cat. No. 54127) is installed in the mounting plate, where the hose fitting connects to
the machine-mount base.
To remove the mounting stud and hose fitting assembly, proceed as follows:
1. Remove the four screws and lockwashers that secure the mounting plate to the underside of
the machine-mount base.
2. Remove the mounting plate containing the mounting stud and the hose fitting, with O-ring in
place.
To install the mounting stud and hose fitting assembly, proceed as follows:
1. Lubricate O-ring and its housing in the mounting plate with a thin coat of Ringlube lubricating
compound (Cat. No. 2M182).
2. Place the mounting stud and hose fitting assembly flat (O-ring) side against the underside of
the machine-mount base. Make sure that the mounting stud is at the front end of the gun, and
the hose fitting is pointing to the rear of the gun. Align the holes in the mounting plate with the
holes on the underside of the machine-mount base.
3. Insert the four lockwashers and screws in the holes on the mounting plate and engage the
screws in the threaded holes in the machine-mount base. Tighten the screws to secure the
assembly.
7-27
Plasma Gas Hose Fitting (See Figure 7.8)
The plasma gas hose fitting is used to connect the plasma gas hose to the gun. When it is
assembled initially to the machine-mount base at the factory, a sealant is used on the mating
threads. Do not remove this fitting except to reapply sealant on a loose connection, or to replace a
damaged fitting.
To remove the plasma gas hose fitting, proceed as follows:
1. Loosen the plasma gas hose fitting, applying a suitable wrench to the hex nut at the base of the
fitting.
2. Unscrew the fitting carefully and remove it.
To install the plasma gas hose fitting, proceed as follows:
1. Clean both threaded areas thoroughly with cleaning solvent.
2. Prime the mating threads with Locquic Primer Grade T. Apply a coating of Loctite
Threadlocker 271 Sealant to the mating threads.
3. Screw the plasma gas hose fitting into place and tighten it with a wrench.
POWDER PORT HARDWARE
Sulzer Metcos 9MB plasma spray guns are delivered with dual port hardware.
Quad powder port hardware is also available, as an option. The Quad Powder Port Clamp (Cat.
No. 9MB964) allows for quadruple-port powder discharge operation. The Quad Powder Port Air
Jet Assembly (Cat. No. 9MB950) allows for quadruple-port powder discharge operation and
integrates workpiece cooling capability. Refer to the Optional Equipment section for more details.
Installing Dual Powder Port Hardware (See Figure 7.9)
Dual powder port hardware supplied with the gun includes the following:
Quantity Cat. No. Description
2 3M331 Swivel Connector
2 9MB202 Powder Port Stem
2 9MB210 # 2 Powder Port
2 9MB982 # 2 Mounting Block
1 9MB961 Dual Powder Port Clamp. Includes: one clamp screw (Reference 10364
in 9MBH/9MBHE Hardware kit, Cat. No. 54128, and in 9MBM
Hardware Kit, Cat. No. 54212); and two shoulder screws (Reference
37251 in 9MBH/9MBHE Hardware Kit, Cat. No. 54128, and in
9MBM Hardware Kit, Cat. No. 54212)
7-28
To install dual powder port hardware, proceed as follows:
1. Select the powder port required for the plasma spray coating application (# 2 powder port
supplied or other), as shown in the Spraying Tables at the end of this manual.
Figure 7.9 Dual Powder Port Hardware Installation
NOTE
To remove existing powder port hardware, refer to
Powder Port Replacement, in this section.
2. Fasten an appropriate mounting block (# 2 mounting block supplied or other) to each position
on the dual powder port clamp (Cat. No. 9MB961), using the shoulder screw (Reference
37251 in 9MBH/9MBHE Hardware Kit, Cat. No. 54128, and in 9MBM Hardware Kit, Cat.
No. 54212) supplied with the clamp.
NOTE
A mounting block can be fastened only one way onto the
powder port clamp. The step in the mounting block fits
into the notch on the powder port clamp. The through
hole and the blind hole in the mounting block can be
mated only one way to the internal screw thread and the
locating pin on the powder port clamp. This aligns the
powder port so that it directs the powder flow at the
correct angle into the plasma stream.
SWIVEL CONNECTORS
POWDER PORT STEMS
MOUNTING
BLOCK
DUAL POWDER PORT
CLAMP
CLAMP SCREW
MOUNTING BLOCK
SHOULDER SCREW
POWDER
PORT
NOZZLE
7-29
3. Insert an appropriate powder port, tip first, into the countersunk hole in the overhanging part
of each mounting block. Thread a powder port stem (Cat. No. 3M202) into each mounting
block and tighten to secure the powder port.
CAUTION
Powder ports and mounting blocks have engraved
mating numbers. Assembling a powder port and
mounting block of different mating numbers will
yield coating results that are different from those
documented by Sulzer Metco.
4. Install the dual powder port clamp onto the gun nozzle, powder ports facing out, pushing it
firmly against the nozzle shoulder. Secure with the clamp screw (Reference 10364 in 9MBH/
9MBHE Hardware Kit, Cat. No. 54128, and in 9MBM Hardware Kit, Cat. No. 54212)
supplied with the clamp.
5. Using two wrenches, fasten a swivel connector (Cat. No. 3M331) to each powder port stem.
6. Connect a powder feed hose (supplied with powder feed unit) to each swivel connector.
Powder Port Replacement (See Figure 7.9)
To replace one powder port with an identical powder port, proceed as follows:
1. Disconnect the powder feed hose from the swivel connector.
2. Using two wrenches, disconnect the swivel connector from the powder port stem.
3. Remove the powder port stem from the mounting block.
4. Remove the powder port from the mounting block.
5. Install the replacement powder port in the original mounting block.
6. Install the powder port stem into the mounting block to secure the powder port.
7. Using two wrenches, fasten the swivel connector to the powder port stem.
8. Connect the powder feed hose to the swivel connector.
To replace one powder port assembly with a different powder port assembly, proceed as
follows:
1. Disconnect the powder feed hose from the swivel connector.
2. Using two wrenches, disconnect the swivel connector from the powder port stem.
3. Remove the powder port assembly (powder port stem, powder port and mounting block) from
the powder port clamp by removing the shoulder screw from the mounting block.
4. Disconnect the powder port stem from the mounting block.
5. Insert the new powder port, tip first, into its matching mounting block. Thread the powder port
stem into the new mounting block and tighten to secure the new powder port.
6. Install the new powder port assembly on the powder port clamp.
7. Using two wrenches, fasten the swivel connector to the powder port stem.
8. Connect the powder feed hose to the swivel connector.
8-1
SECTION 8
RECOMMENDED SPARE PARTS
List of Tables
All 9MB Gun Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Consumable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
9MBH/9MBHE Handheld Guns Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
9MBM Machine-Mounted Gun Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
With normal use, certain parts of Sulzer Metcos 9MB plasma spray guns will routinely require
replacement. The availability of these parts can eliminate unnecessary downtime. The following is
a list of spare parts recommended for each variation, and the quantity to be kept on hand:
ALL 9MB GUN VARIATIONS
Qty Cat. No. Description
2 3M331 Swivel Connector
1 9MB961 Dual Powder Port Clamp. Includes: one clamp screw (Reference 10364
in 9MBH/9MBHE Hardware kit, Cat. No. 54128, and in 9MBM
Hardware Kit, Cat. No. 54212); and two shoulder screws (Reference
37251 in 9MBH/9MBHE Hardware Kit, Cat. No. 54128, and in
9MBM Hardware Kit, Cat. No. 54212).
1 9MB15 Water Channeling Head
1 9MB50 Argon Front Insulator (2 Gas Holes)
1 9MB55 Nitrogen Front Insulator
1 9MB60 Argon Front Insulator (6 Gas Holes)
8-2
CONSUMABLE ITEMS
O-RINGS
NOTE
Under normal operating conditions, powder ports,
nozzles, and electrodes must be replaced on a regular
basis. They are considered consumable items.
Spares of these parts should be kept on hand according
to spraying schedules. Refer to the Replacement Parts
section of this manual for a complete listing. It is
strongly recommended to keep spares of the GP
(General Purpose) nozzle. Depending on specific
spraying applications, other powder ports, nozzles and
electrodes may need to be kept as spares.
3 9MB972 #2 Powder Port Assembly
(Includes Cat. Nos. 3M202, 3M210, 9MB982)
2 3M7-GP GP Nozzle Assembly
2 9MB730A 730 Nozzle Assembly
3 9MB63 63 Electrode Assembly
1 54127 9MBM/9MBH Reseal Kit
This is a complete set of O-rings for any 9MB plasma spray gun
variation (all dimensions in inches):
Reference
03018
05708
06487
09879
14551
19716
21469
21470
21471
29520
29521
I.D.
0.239
0.426
0.864
0.739
1.239
0.489
0.614
0.426
1.114
0.850
0.926
C/S
0.070
0.070
0.070
0.070
0.070
0.070
0.070
0.070
0.070
0.045
0.070
Material
Buna N
Buna N
Buna N
Buna N
Buna N
Black Viton
Black Viton
Black Viton
Black Viton
Black Viton
Buna N
Qty
4
4
2
4
2
2
4
4
4
2
4
8-3
9MBH/9MBHE HANDHELD GUNS ONLY
9MBM MACHINE-MOUNTED GUN ONLY
1 54128 9MBH/9MBHE Hardware Kit
This is a complete set of hardware items for the 9MBH and 9MBHE
handheld plasma spray guns (all dimensions in inches):
Reference
13120
14928
14978
22489
22490
05990
00481
03674
00487
37251
10364
19525
13752
Description
Screw 8-32 1/4 Fillister Head
Shoulder Screw 8/32 5/32
Spring Washer Crescent Curved
0.189 I.D. 0.312 O.D. 0.004 Thick 0.062 H.
Screw 10-32 11/16 Fillister Head
Screw 10-24 1 1/8 Fillister Head
Screw 1/4-20 7/8 Round Head
Lock Washer Internal Tooth
0.256 I.D. 0.466 O.D. 0.025 Thick
Screw 1/4-20 1 1/2 Fillister Head
Hex Nut 1/4-20
Shoulder Screw 8-32 3/16
Clamp Screw 10-24 1 13/64 Knurled Head
Clamp Screw 10-32 3/4 Truss Head
Set Screw 10-24 3/8 Hex Socket
Qty
2
2
2
6
2
4
4
4
4
4
2
1
2
1 54212 9MBM Hardware Kit
This is a complete set of hardware items for the 9MBM machine-mounted
plasma spray gun (all dimensions in inches):
Reference
13367
00481
15002
14988
37251
10364
13752
Description
Screw 1/4-20 1/2 Round Head
Lock Washer Internal Tooth
0.256 I.D. 0.466 O.D. 0.025 Thick
Plug Screw 9/16-18 41/64 (Insulating)
Clamp Screw 1/4-20 1/2 Special Head
Shoulder Screw 8-32 3/16
Clamp Screw 10-24 1 13/64 Knurled Head
Set Screw 10-24 3/8 Hex Socket
Qty
8
8
1
1
4
2
2
9-1
SECTION 9
REPLACEMENT PARTS
List of Tables
Front Gun Section Water Channeling Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Front Gun Section Nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Two-Piece Nozzle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Front Gun Section Electrode and Insulator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Powder Port Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Quad Powder Port Air Jet Assembly (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9MBH/9MBHE Handheld Guns Gun Handle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9MBM Machine-Mounted Gun Machine-Mount Base Assembly. . . . . . . . . . . . . . . . . . . 9-14
9MBM Machine-Mounted Gun Special Mounting Hardware (Option) . . . . . . . . . . . . . 9-15
9MBH/9MBHE Handheld Guns Special Mounting Hardware (Option) . . . . . . . . . . . . 9-16
7MH Hose and Cable Unit, 15 feet (4.5 m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
7MH-25 Hose and Cable Unit, 25 feet (7.6 m) (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Hose and Cable Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
9MBH/9MBHE Handheld Guns Gun Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Tools and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Miscelaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
9-2
Figure 9.1 9MB Plasma Spray Guns
FRONT GUN SECTION
NOZZLE
GUN HANDLE
FRONT GUN SECTION
NOZZLE
ELECTRODE AND INSULATOR ASSEMBLY MACHINE-MOUNT BASE
9MBM MACHINE-MOUNTED GUN
9MBH AND 9MBHE HANDHELD GUNS
9-3
FRONT GUN SECTION WATER CHANNELING HEAD
Figure 9.2 Front Gun Section Water Channeling Head
Cat. No. Description
9MB15 Water Channeling Head
* NOTE: This O-ring is delivered
cemented in place on the water
channeling head (Cat. No.
9MB15). It is also available as
part of the 9MBM/9MBH Reseal
Kit (Cat. No. 54127). O-rings
cannot be supplied individually.
9MB15
O-RING
29520*
9-4
FRONT GUN SECTION NOZZLE

9MB8 Nozzle Nut
ONE-PIECE NOZZLES
3M7-G G Nozzle Assembly
3M7-GE GE Nozzle Assembly
3M7-GH GH Nozzle Assembly
3M7-GP GP Nozzle Assembly
7M700 700 Nozzle Assembly
TWO-PIECE NOZZLES
(See also Two-Piece Nozzle Assembly Replacement Parts)
9MB720A 720 Nozzle Assembly
9-5
Figure 9.3 Front Gun Section Nozzle
(One-Piece Nozzle Shown)
9MB8
NOZZLE ASSEMBLY
(SEE NOZZLE LIST)
21471*
21469*
* NOTE: O-rings are mounted on all nozzle assemblies (sold under catalog
numbers listed). They are also available as part of the 9MBM/9MBH Reseal
Kit (Cat. No. 54127). O-rings cannot be supplied individually.
O-RING
O-RING
9-6
TWO-PIECE NOZZLE ASSEMBLY
*NOTE
O-rings are mounted on all nozzle assemblies (sold under
catalog numbers listed). They are also available as part of
the 9MBM/9MBH Reseal Kit (Cat. No. 54127). O-rings
cannot be supplied individually.
Figure 9.4 Front Gun Section Nozzle
(Two-Piece Nozzle Shown)
(1)
Nozzle Assembly
Catalog Number
(2)
Nozzle Body
Catalog Number
(3)
Nozzle Shell
Catalog Number
(4)
O-Ring
Reference*
9MB720A 9MB720B 9MB720C 19716*
9MB724A 9MB724B 9MB724C 21470*
9MB727A 9MB727B 9MB727C 19716*
9MB728A 9MB728B 9MB728C 21470*
9MB730A 9MB730B 9MB730C 19716*
9MB731A 9MB731B 9MB731C 21470*
9MB732A 9MB732B 9MB732C 19716*
9MB733A 9MB733B 9MB733C 21470*
9MB738A 9MB738B 9MB738C 21470*
21469*
NOZZLE BODY
NOZZLE SHELL
21471*
O-RING
(SEE LIST)*
O-RING
O-RING
(1) NOZZLE ASSEMBLY
(3)
(2)
(4)
9-7
FRONT GUN SECTION ELECTRODE AND INSULATOR ASSEMBLY
*NOTE
O-rings are mounted on their respective assemblies (sold
under catalog numbers listed). They are also available as
part of the 9MBM/9MBH Reseal Kit (Cat. No. 54127).
O-rings cannot be supplied individually.
Figure 9.5 Front Gun Section Electrode and Insulator Assembly
7M14 Electrode Locking Nut
7M17 Electrode Holder Nut
9MB18 Electrode Holder Assembly
9MB50 Front Insulator Assembly 2-Hole Argon (Includes O-Ring Reference 29521*)
9MB55 Front Insulator Assembly Nitrogen (Includes O-Ring Reference 29521*)
9MB60 Front Insulator Assembly 6-Hole Argon (Includes O-Ring Reference 29521*)
9MB63 63 Electrode Assembly (Includes O-Ring Reference 29470*)
9MB64 P Electrode Assembly (Includes O-Ring Reference 29470*)
9MB166 Rear Insulator
9MB693 Electrode and Insulator Assembly (Includes Cat. Nos. 9MB63 and 9MB50)
9MB63
9MB64
7M14
9MB50
9MB55
9MB60
9MB166
7M17
9MB18
21470*
29521*
06487*
09879*
03018*
05708*
09879*
05708*
21469*
9-8
POWDER PORT HARDWARE
3M202 Powder Port Stem
3M203 #3 Powder Port
9MB997 #7 Powder Port
3M331 Swivel Connector
9MB963 Swivel Connector (Option) (Not Shown)
9MB950 Quad Powder Port Air Jet Assembly (Option) (See replacement parts in this section)
9MB961 Dual Powder Port Clamp (Includes One Clamp Screw, Reference 10364, and Two
Shoulder Screws, Reference 37251)*
9MB964 Quad Powder Port Clamp (Without Air Jet Heads) (Option) (Not Shown)
9MB971 #1 Powder Port Assembly (Not Shown)
(Includes Powder Feed Tube, Powder Port, and Mounting Block)
9MB972 #2 Powder Port Assembly
(Includes Cat. Nos. 3M202, 9MB997, 9MB987)
9MB982 #2 Mounting Block
9-9
Figure 9.6 Powder Port Hardware
(Dual Powder Port Hardware Shown)
*NOTE
One clamp screw (Reference 10364) and two shoulder
screws (Reference 37251) are supplied with the Dual
Powder Port Clamp (Cat. No. 9MB961). These items are
also available as part of the 9MBH/9MBHE Hardware
Kit (Cat. No. 54129) and the 9MBM Hardware Kit (Cat.
No. 54212). They cannot be supplied individually.
3M331
3M202
9MB961
CLAMP SCREW
10364*
POWDER PORT
(SEE LIST)
MOUNTING BLOCK
(SEE LIST)
SHOULDER SCREW
37251*
9-10
CAT. NO. 9MB950 QUAD POWDER PORT AIR JET ASSEMBLY (OPTION)
Figure 9.7 (Sheet 1 of 2) Cat. No. 9MB950 Quad Powder Port Air Jet Assembly
7M150 Air Supply Hose
2PSA35 Wye Assembly (Includes two air hose connections, Reference 00176***, and
one air hose connection, Reference 00178***)
2PSA40 Air Nozzle Hose Assembly
3M782 Left Pivot Block
3M783 Right Pivot Block
2PSA30 Air Nozzle
9MB951 Air Jet Head and Quad Powder Port Clamp (Includes four shoulder screws,
Reference 37251**, and one clamp screw, Reference 10364**)
PS43 Hex Key
9MB955 Instructions for Cat. No. 9MB950 Quad Powder Port Air Jet Assembly
SHOULDER SCREW
37251**
NUT
13747*
3M783
FLAT WASHER
10436*
CLAMP SCREW
13773*
9MB951
10364**
CLAMP SCREW
AIR NOZZLE
SET SCREW
13752*
3M782
2PSA30
9-11
Figure 9.7 (Sheet 2 of 2) Cat. No. 9MB950 Quad Powder Port Air Jet Assembly
NOTES
* These items are available as part of the 9MBH/9MBHE
Hardware Kit (Cat. No. 54129) and the 9MBM Hardware
Kit (Cat. No. 54212). They cannot be supplied
individually.
** These items are supplied with the Air Jet Head and
Quad Port Clamp (Cat. No. 9MB951). They are also
available as part of the 9MBH/9MBHE Hardware Kit
(Cat. No. 54129) and the 9MBM Hardware Kit (Cat. No.
54212). They cannot be supplied individually.
*** These items are supplied with the Wye Assembly
(Cat. No. 2PSA35). They are also available as part of the
9MBH/9MBHE Hardware Kit (Cat. No. 54129) and the
9MBM Hardware Kit (Cat. No. 54212). They cannot be
supplied individually.
7M150
AIR HOSE CONNECTION
00178***
2PSA35
AIR HOSE CONNECTION
00176***
2PSA40
PS43
9-12
9MBH/9MBHE GUN HANDLE ASSEMBLY
CAT. NO. 9MB550 FOR 9MBH HANDHELD PLASMA SPRAY GUN
CAT. NO. 56790 FOR 9MBHE HANDHELD PLASMA SPRAY GUN
(All replacement parts listed are common to both variations, except where indicated.)
Figure 9.8 (Sheet 1 of 2) Gun Handle Assembly Left Half Handle Outside View
7M25 Front Gun Body Assembly
7M30 Rear Gun Body Assembly
7M32 Insulator (Not Shown)
7M40 Switch and Cable Assembly (for 9MBH Plasma Spray Gun)
56336 Switch and Cable Assembly (for 9MBHE Plasma Spray Gun) (Not Shown)
7M58 Front Gun Body Hose Assembly (Includes O-ring Reference 3018*)
3M670 Switch Boot
9MB74 Name Plate
9MB95 Support Bracket
9MB575 Left Half and Right Half Handle Assembly (Includes: left half and right half molded
handles; handle fastening screws, three short and one long, References 22489* and
22490*; name plate mounting screw, Reference 13120*; name plate shoulder screw,
Reference 14928*; spring washer, Reference 14978*; and Name Plate, Cat. No.
9MB74)
9MB670 Electrode Holder Clamp Screw and Retaining Ring Package (Includes clamp screw,
retaining ring, and assembly instructions)
13120* 9MB74
14928*
14978*
22489*
22489*
9MB575
22489*
22490*
9-13
Figure 9.8 (Sheet 2 of 2) Gun Handle Assembly Right Half Handle Inside View
(Cat. No. 9MB550 for 9MBH Handheld Plasma Spray Gun Shown)
SUPPORT BRACKET 9MB95
MOUNTING SCREW 05970*
LOCK WASHER 00481*
9MB670
7M25 7M30
3M670
7M40
56336 (NOT SHOWN)
9MB575
O-RING**
(SEE DETAIL)
DETAIL
3018**
7M58
**NOTE
This O-ring is mounted on the Front
Gun Body Hose Assembly (Cat.
No. 7M58). It is also available as
part of the 9MBM/9MBH Reseal
Kit (Cat. No. 54127). It cannot be
7M58
O-RING
*NOTE
These items are available as part of
the 9MBH/9MBHE Hardware Kit
(Cat. No. 54129). They cannot be
9-14
CAT. NO. 9MB165 MACHINE-MOUNT BASE ASSEMBLY
(For 9MBM Machine-Mounted Plasma Spray Gun)
Figure 9.9 Cat. No. 9MB165 Machine-Mount Base Assembly
NOTES
* These items are available as part of the 9MBM Hardware Kit
(Cat. No. 54212). They cannot be supplied individually.
** O-ring (Reference 14551) is mounted on the
Machine-mount Base Assembly (Cat. No. 9MB165). O-ring
(Reference 19716) is mounted on the Machine-mount Base
Assembly (Cat. No. 9MB165) and on the Mounting Stud and
Hose Fitting Assembly (Cat. No. 9MB335). Both are also
available as part of the 9MBM/9MBH Reseal Kit (Cat. No.
54127). They cannot be supplied individually.
7M135 Electrode Holder Clamp and Hose Fitting
9MB142 Locking Ring Assembly
7M144 Current Connection Insulator (Not Shown)
9MB208 Plasma Gas Hose Fitting
7M301 Cable Support Strap Assembly (Includes Handle) (Option)
9MB335 Mounting Stud and Hose Fitting Assembly
7M605 Right-Angle Cable Support Bracket Assembly (Option) (Not Shown)
14551**
19716**
9MB335
SCREW 13367*
LOCK WASHER 00481*
PLUG SCREW 15002*
CLAMP SCREW 14988*
9MB142
7M301 (OPTION)
7M135
9MB208
O-RING
O-RING
9-15
9MBM MACHINE-MOUNTED GUN SPECIAL MOUNTING HARDWARE
CAT. NO. 55788 MOUNTING BAR ASSEMBLY (OPTION)
CAT. NO. 7M568 MOUNTING ADAPTER ASSEMBLY (OPTION)
Figure 9.10 9MBM Machine-Mounted Gun Special Mounting Hardware
*NOTE
These items are mounted in their respective assemblies.
They cannot be supplied individually.
19754*
12733*
CLAMP SCREW
10558*
FLAT WASHER
00942*
FLAT WASHER
00942*
CLAMP SCREW
10558*
MOUNTING ADAPTER ASSEMBLY (OPTION)
MOUNTING BAR ASSEMBLY (OPTION)
CAT. NO. 7M568
CAT. NO. 55788 NOTE
When the optional Mounting Adapter
Assembly (Cat. No. 7M568) is
attached to the optional Mounting Bar
Assembly (Cat. No. 55788) as shown,
the 9MBM machine-mounted plasma
spray gun can be rotated 360.
ADAPTER BAR ASSEMBLY
MOUNTING BAR
9-16
9MBH/9MBHE HANDHELD GUNS SPECIAL MOUNTING HARDWARE
CAT. NO. 7M90 TOOL POST BRACKET ASSEMBLY (OPTION)
CAT. NO. 6P125 TOOL POST FIXTURE ASSEMBLY (OPTION)
Figure 9.11 9MBH/9MBHE Handheld Guns Special Mounting Hardware
*NOTE
These items are mounted in their respective assemblies.
They cannot be supplied individually.
TOOL POST BRACKET ASSEMBLY (OPTION)
CAT. NO. 7M90
TOOL POST FIXTURE ASSEMBLY (OPTION)
CAT. NO. 6P125
TOOL POST BRACKET
15455*
INSULATOR WASHER
14944* NUT
00609*
LOCK WASHER
00608*
INSULATOR
14943*
FLAT WASHER
14940*
TOOL POST BRACKET
STUD
14945*
TOOL POST
FIXTURE BODY
02143*
TOOL POST
CLAMP BAR
01675*
JAM NUT
01676*
LOCK WASHER
01694*
FLAT WASHER
01695*
CLAMP SCREW
02279*
9-17

7MH HOSE AND CABLE UNIT, 15 feet (4.5 m) (Not Shown)
7MH-25 HOSE AND CABLE UNIT, 25 feet (7.6 m) (OPTION) (Not Shown)
HOSE AND CABLE OPTIONS (Not Shown)
7MH10 Nozzle Water-Cooled Electric Cable Assembly, 15 feet (4.5 m)
7MH20 Electrode Water-Cooled Electric Cable Assembly, 15 feet (4.5 m)
7MH50 Plasma Gas Hose Assembly, 19 feet (5.8 m)
7MH141 Nozzle Water-Cooled Electric Cable Coupling
AP200 Electrode Water-Cooled Electric Cable Coupling
2M380 Spiral Cable Wrapping, 37 feet (10.9 m) (Includes Instructions)
7M144 Current Connection Insulator
7MH119 Insulator
7MH140 Water-Cooled Electric Cable Coupling Kit (Includes Cat. Nos. AP200,
7MH141, 7MH119, 7M144, and Instructions)
9-18
GUN CONTROL CABLES (For 9MBH/9MBHE Handheld Guns) (Not Shown)
TOOLS AND LUBRICANTS (Not Shown)
MISCELANEOUS (Not Shown)
7M195 Gun Control Cable, 18 feet (5.5 m) (for 9MBH Gun Only)
7M199 Gun Control Unit, 28 feet (8.5 m) (For 9MBH Gun Only) (Option)
56255 Gun Control Cable, 27 feet (8.2 m) (for 9MBHE Gun Only)
10MB104 Electrode Nut Spanner
7MB108 Electrode Puller Pliers
9MB852 Nozzle Wrench (Required for Two-Piece Nozzles)
55866 Nozzle Nut and Locking Ring Wrench
2M182 Ringlube Lubricating Compound
9MB266 Gun Suspension Assembly (For 9MBH and 9MBHE Guns) (Option)
55789 Hook and Mounting Block (For 9MBH and 9MBHE Guns) (Option)
54127 9MBM/9MBH Reseal Kit (Details in Recommended Spare Parts section)
54128 9MBH/9MBHE Hardware Kit (Details in Recommended Spare Parts section)
54212 9MBM Hardware Kit (Details in Recommended Spare Parts section)
9MB888 Instruction Manual for 9MB Plasma Spray Guns (English)
54359 Instruction Manual for 9MB Plasma Spray Guns (German) (Option)
54244 Instruction Manual for 9MB Plasma Spray Guns (French) (Option)
56015 Instruction Manual for 9MB Plasma Spray Guns (Italian) (Option)
BULZER NETCO
Doc. 56347, Issue b
Plasma Spraying Tables
GENERAL
The Spraying Tables which follow are based on extensive laboratory and field experience. The
parameters listed for each powder will produce sound, reliable coatings at optimum deposit
efficiency.
This does not mean that the user is restricted to the parameters shown. These should be used as a
reasonable starting point and, if necessary, modified to obtain optimum results for your
application.
Proper use of the Spraying Tables requires that the operator be familiar with all of the components
used in a Sulzer Metco Plasma Spray System. In this way, the equipment can be set up in
accordance with the parameters shown.
Refer to the Spraying Table Selector below to find parameters for the fuel gas or gases used.
Spraying tables list parameters in U.S. units, followed by the same parameters in metric units.
Each spraying table contains notes with special instructions. These instructions are important and
should be followed to achieve optimum spraying results.
ABBREVIATIONS
g/min grams per minute
lb/h pounds per hour
NLPM Normal Liters Per Minute (0 C, 1013.25 mbar)
PSI Pounds per Square Inch
SCFH Standard Cubic Feet per Hour (70 F, 14.7 PSI)
Spraying Table Selector
Table 1 Pure Argon
Table 2 Argon / Hydrogen
Table 3 Argon / Helium
Table 4 Pure Nitrogen
Table 5 Nitrogen / Hydrogen
TABLE 1 PURE ARGON
T1-1 Doc. 56347, Issue b
U.S. UNITS
NOTES:
(1) Set primary gas pressure to 75 psi. Set air pressure to 85 psi. Install Argon (A) insulator in the gun. Set primary gas pressure with
gas flowing.
(2) Voltage reading is taken at the distribution unit. A voltage reading can also be obtained directly from the gun, using a voltage
divider (Cat. No. 9MCD600, supplied only with the 9MCD distribution unit), and a 9MC plasma control unit. Gun voltage usually
reads 3 to 10 volts lower than the distribution unit voltage. Distribution unit voltage varies with cable length. (The standard 7MH
hose and cable unit is 15 feet long.)
(3) Use BLACK feed hose. For (*), use ORANGE hose. Powder port or nozzle buildup may occur when spraying for 1/2 hour or
longer. Brush off any accumulation before continuing. DO NOT FILE.
(4) Pickup shaft selection depends on feed rate. Refer to powder feeder manual for selection procedure.
(5) Optimum figures shown for coating quality. Higher or lower spray rates may require carrier gas flow adjustment to prevent
clogging.
(6) Voltage shown in table is the optimum achievable with new gun hardware. The allowable range for all voltages listed is 5 volts.
Voltage will decrease as hardware (nozzle and electrode) becomes worn from use.
(7) When using a Type 4MP Powder Feeder, refer to the 4MP carrier gas flow conversion chart for proper carrier gas (FMR) flow
settings. Set argon carrier gas pressure to 60 psi.
Material Gun Hardware and Parameters 9MP Feeder Setup
Nozzle Type Gas Flow
SCFH
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
Inch
Carr.
Gas
Flow
SCFH
(7)
Set
Vibr.
Air
PSI
Pickup
Shaft
Type
(4)
Spray
Rate
lb/h
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec. Paral/
Cross
Inch
Set
Air
PSI
43F-NS 704 724 112 -- 1000 40-55 -- -- 5 2.5 20.5 5 A 6
43VF-NS 704 724 225 -- 1000 45-55 4 40 5 2.5 20.5 5 A 6
45VF-NS 704 724 225 -- 1000 45-55 5 30-50 5 2.5 20.5 5 A 6
51F-NS 707 727 126 -- 400 65-70 -- -- 1 3-5 13.5 15 A 9
66F-NS 704 724 43 -- 1000 32-37 Paral 40 3 4 10.5 15 A 6
68F-NS-1 704 724 43 -- 1000 32-37 -- -- 3 4 10.5 5 A 6
707 727 43 -- 1000 32-37 -- -- 3 4 13.5 5 A 6
71VF-NS 704 724 225 -- 1000 45-55 -- -- 5 2.5 20.5 5 B 6
71VF-NS-1 704 724 212 -- 1000 45-50 Paral 75 5 3.5 20.5 5 B 6
73FNS-1/-2 704 724 225 -- 1000 45-55 -- -- 5 2.5 20.5 5 B 6
73SF-NS 704 724 290 -- 800 45-55 -- -- 5 2.5 20.5 5 B 6
81VF-NS 704 724 112 -- 1000 45-55 4 50 5 2.5 20.5 5 A 6
83VF-NS 704 727 112 -- 1000 45-55 Paral 50 5 2.5-
3.5
13.5 5 A 6
TABLE 1 PURE ARGON
METRIC UNITS
NOTES:
(1) Set primary gas pressure to 5.1 bars. Set air pressure to 5.8 bars. Install argon (A) insulator in the gun. Set primary gas pressure
with gas flowing.
hose and cable unit is 4.5 m long.)
clogging.
settings. Set argon carrier gas pressure to 4.1 bars.
Nozzle Type Gas Flow
NLPM
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
mm
Carr.
Gas
Flow
NLPM
Set
Vibr.
Air
bar
Pickup
Shaft
Type
(4)
Spray
Rate
g/min
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec. Paral/
Cross
mm
Set
Air
bar
(7)
43F-NS 704 724 43 -- 1000 40-55 -- -- 5 63 20.5 0.3 A 45
43VF-NS 704 724 98 -- 1000 45-55 101 2.7 5 63 20.5 0.3 A 45
45VF-NS 704 724 98 -- 1000 45-55 127 2-3.4 5 63 20.5 0.3 A 45
51F-NS 707 727 55 -- 400 65-70 -- -- 1 76-
127
13.5 1.0 A 69
66F-NS 704 724 19 -- 1000 32-37 Paral 2.7 3 101 10.5 1.0 A 45
68F-NS-1 704 724 19 -- 1000 32-37 -- -- 3 101 10.5 0.3 A 45
707 727 19 -- 1000 32-37 -- -- 3 101 10.5 0.3 A 45
71VF-NS 704 724 98 -- 1000 45-55 -- -- 5 63 20.5 0.3 B 45
71VF-NS-1 704 724 93 -- 1000 45-50 Paral 5.1 5 88 20.5 0.3 B 45
73FNS-1/-2 704 724 98 -- 1000 45-55 -- -- 5 63 20.5 0.3 B 45
73SF-NS 704 724 127 -- 800 45-55 -- -- 5 63 20.5 0.3 B 45
81VF-NS 704 724 49 -- 1000 45-55 101 3.4 5 63 20.5 0.3 A 45
83VF-NS 704 727 49 -- 1000 45-55 Paral 3.4 5 63-88 13.5 0.3 A 45
TABLE 2 ARGON / HYDROGEN
T2-1
Doc. 56347, Issue b
U.S. UNITS
NOTES:
(1) Set primary gas pressure to 75 psi. Set secondary gas pressure to 50 psi. Set air pressure to 85 psi. For soft start, set Argon
pressure to 48 psi. Install Argon (A) insulator in the gun. Set primary gas pressure with gas flowing.
hose and cable unit is 15 feet long.) Adjust secondary flow to attain required voltage.
clogging.
(7) When using a Type 4MP or 4MP Dual Powder Feeder, refer to the 4MP carrier gas flow conversion chart for proper carrier gas
(FMR) flow settings. Set argon carrier gas pressure to 60 psi.
Nozzle
Type
Gas Flows
SCFH
(1)
Set
Amp.
(DC)
Voltage
Range
DistrIbu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
Inch
Carr.
Gas
Flow
SCFH
(7)
Set
Vibr.
Air
PSI
Pickup
Shaft
Type
(4)
Spray
Rate
lb/h
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
H
2
Paral/
Cross
Inch
Set
Air
PSI
34F GP 733 111 17 500 70-80 -- -- 2 6 13.5 5 A 8.5
41F-NS GE 731 111 6 500 50-60 4 35/50 2 2-2.5 13.5 5 A 9.5
707 727 111 11 600 45-50 4 35 2 2-2.5 13.5 15 A 20
43C-NS GH 732 111 5 400 55-65 -- -- 2 4-6 13.5 5 A 14
43F-NS GH 732 167 5 500 60-70 -- -- 2 4-6 13.5 5 A 16
43VF-NS GE 731 167 7 500 45-55 4 40 2 2.5 20.5 5 A 7
44 GH 732 111 5 500 55-65 -- -- 2 4-6 13.5 5 A 20
45C-NS GE 731 111 17 400 65-70 -- -- 2 4.5-5.5 13.5 5 A 7
45VF-NS GE 731 167 7 500 45-55 5 35/50 2 2-2.5 20.5 5 A 6.5
51NS GH 732 167 5 500 60-70 -- -- 2 4-6 13.5 5 A 14.5
51F-NS GE 731 167 19 450 65-75 -- -- 1 3-5 13.5 25 A 7
52C-NS GH 732 89 15 500 64-70 -- -- 1 4-6 13.5 5 A 10
54NS GH 732 167 10 500 70-75 -- -- 1 4-6 13.5 5 A 6.5
700 720 89 10 600 65-70 -- -- 2 4-6 13.5 5 A 7.9
55 GH 732 167 5 500 60-70 -- -- 1 4-6 13.5 5 A 15
56C-NS GH 732 89 10 500 55-65 -- -- 2 4-6 13.5 5 A 14
56F-NS GH 732 167 5 500 60-70 -- -- 2 4-6 13.5 5 A 15
57NS GH 732 84 15 500 60-70 4.5 35 2 2.5 13.5 5 A 6
58NS GH 732 84 15 500 60-70 4.5 35 2 2.5 13.5 5 A 6
T2-2
Doc. 56347, Issue b
U.S. UNITS
NOTES:
clogging.
Nozzle
Type
Gas Flows
SCFH
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
Inch
Carr.
Flows
SCFH
(7)
Set
Vibr.
Air
PSI
Pickup
Shaft
Type
(4)
Spray
Rate
lb/h
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
H
2
Paral/
Cross
Inch
Set Air
PSI
63NS GE 731 111 17 700 60-70 -- -- 2 4 13.5 5 A 9.5
GH 732 90 15 500 64-70 -- -- 2 3-5 13.5 5 A 9.5
GH 732 90 15 500 64-70 -- -- 2 4 13.5 5 A 22
64 GH 732 90 15 400 65-70 Paral 50 2 4 13.5 5 A 10
GH 732 90 15 500 64-70 Paral 50 2 4 13.5 15 A 22
66F-NS GH 732 167 10 500 70-75 -- -- 2 4 13.5 15 A 6
68F-NS-1 GH 732 167 10 500 70-75 -- -- 2 4 13.5 15 A 6
70C-NS GH 732 90 15 500 60-70 -- -- 2 3-5 13.5 5 A 10
71NS GH 732 111 10 500 60-70 -- -- 2 4 13.5 5 A 17
GP 733 138 17 500 74-80 -- -- 2 2.5-3.5 13.5 5 A 4
71VF-NS GE 731 111 11 400 55-60 -- -- 2 2.5-4 13.5 15 B 8
73F-NS-1/
73F-NS-2
GE 731 178 9 400 50-55 -- -- 2 3 20.5 5 B 11
81NS GH 732 90 15 500 64-70 -- -- 2 3-5 13.5 5 A 10
GP 733 99 17 300 75-80 -- -- 2 3-5 13.5 5 A 5
81VF-NS GH 732 111 10 500 60-70 -- -- 2 2-2.5 13.5 15 A 5.5
GH 732 111 10 500 60-70 -- -- 2 2.5 13.5 15 A 19
700 720 90 15 600 60-70 -- -- 2 2.5 13.5 5 A 18
T2-3
Doc. 56347, Issue b
U.S. UNITS
NOTES:
clogging.
Nozzle
Type
Gas Flows
SCFH
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
Inch
Carr.
Flows
SCFH
(7)
Set
Vibr.
Air
PSI
Pickup
Shaft
Type
(4)
Spray
Rate
lb/h
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
H
2
Paral/
Cross
Inch
Set Air
PSI
101NS GH 732 90 15 500 64-70 -- -- 2 2-4 13.5 25 A 7
101B-NS GH 732 90 25 500 70-80 -- -- 2 3-5 13.5 25 A 7
101SF GH 732 167 15 500 75-80 3.5 75 2 2 26 25 A 3
GP 733 147 19 500 75-80 3.5 75 2 2 26 25 A 3
700 720 90 15 600 65-75 3.5 75 2 3 26 25 A 7
102 GH 732 90 15 500 64-70 -- -- 2 3-4 13.5 25 A 7
105NS-1 GH 732 90 15 500 64-70 -- -- 2 2-4 13.5 25 A 5.5
105SF GH 732 167 15 500 75-80 3.5 75 2 2-2.5 26 25 A 3
GP 733 167 19 500 75-80 3.5 75 2 2-2.5 26 25 A 3
700 720 90 15 600 60-70 3.5 75 2 3 26 25 A 6
105SFP GH 732 167 10 500 75-80 3.5 75 2 2.5 26 25 A 3
700 720 90 15 600 60-70 3.5 75 2 2.5 26 25 A 6
GP 733 167 10 500 75-80 3.5 75 2 2.5 26 25 A 3
106 GH 732 80 15 500 64-70 -- -- 2 2.5 13.5 25 A 5
T2-4
Doc. 56347, Issue b
U.S. UNITS
NOTES:
clogging.
Nozzle
Type
Gas Flows
SCFH
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
Inch
Carr.
Flows
SCFH
(7)
Set
Vibr.
Air
PSI
Pickup
Shaft
Type
(4)
Spray
Rate
lb/h
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
H
2
Paral/
Cross
Inch
Set Air
PSI
106F GH 732 80 15 500 60-70 6 50 2 2.5 13.5 25 A 5
111 GH 732 90 15 500 64-70 -- -- 2 3-4 13.5 5 A 6
130 GH 732 90 15 500 70-80 -- -- 2 4-5 13.5 25 A 5
130SF GH 732 80 20 500 60-70 3.5 50 2 2.5 20.5 25 A 3
131VF G 730 111 15 500 60-70 Paral 50 2 2.5-
3.5
20.5 25 A 3
700 720 90 15 600 60-70 3.5 75 2 3 20.5 25 A 5
GP 733 111 20 500 75-80 7.5 50 2 6 20.5 25 A 3
GP 733 111 20 500 75-80 Paral 50 2 2.5-
3.5
20.5 25 A 3
136F GH 732 80 15 500 64-70 6 50 2 2.5 13.5 25 A 5
143 GE 731 84 17 600 60-70 3 70 2 3 13.5 20 A 5
GE 731 64 15 700 60-70 3 70 2 3 13.5 20 A 10
201NS GH 732 90 15 500 60-70 -- -- 2 2-4 13.5 25 A 6
201B-NS GH 732 90 15 500 60-75 -- -- 2 2-4 13.5 25 A 6.5
T2-5
Doc. 56347, Issue b
U.S. UNITS
NOTES:
clogging.
Nozzle
Type
Gas Flows
SCFH
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
Inch
Carr.
Flows
SCFH
(7)
Set
Vibr.
Air
PSI
Pickup
Shaft
Type
(4)
Spray
Rate
lb/h
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
H
2
Paral/
Cross
Inch
Set Air
PSI
201B-NS-1 GH 732 90 25 500 70-80 -- -- 2 2-2.5 13.5 25 A 12
GH 732 90 25 500 70-80 -- -- 2 2-2.5 13.5 25 A 6
202NS GH 732 90 15 500 64-70 -- -- 2 2.5 13.5 25 A 12
GH 732 90 15 500 64-70 -- -- 2 2.5 13.5 25 A 6
204NS GH 732 90 15 600 64-70 -- -- 2 2.5 13.5 25 A 6
GH 732 90 15 600 64-70 -- -- 2 2.5 13.5 25 A 12
204B-NS G 730 90 15 500 60-70 -- -- 2 2.5 13.5 25 A 6
205NS GH 732 80 15 400 65-75 Paral 50 2 4 13.5 25 A 6
210NS-1 GH 732 80 15 500 64-70 -- -- 2 3 13.5 25 A 5
303NS-1 GH 732 90 15 500 64-70 -- -- 2 4 13.5 25 A 6
311NS GH 732 111 15 500 60-70 Paral 75 6 4 13.5 25 A 8
313NS GH 732 212 10 500 75-85 -- -- 1 5 20.5 25 A 8
320NS GH 732 212 6 500 70-80 Paral 25-30 1 6 18 25 A 7
350NS GH 731 111 17 500 65-70 Paral 70 1 4 13.5 5 A 10
404NS GH 732 111 17 500 64-70 -- -- 1 4-6 13.5 5 A 9.9
410NS GH 732 90 15 500 64-70 -- -- 1 3-5 13.5 5 A 5
T2-6
Doc. 56347, Issue b
U.S. UNITS
NOTES:
clogging.
(8) Secondary gas flow can be adjusted 5 SCFH in order to achieve desired voltage range. DO NOT REDUCE secondary gas flow to
zero, NOR GO ABOVE 25 SCFH.
Nozzle
Type
Gas Flows
SCFH
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
Inch
Carr.
Flows
SCFH
(7)
Set
Vibr.
Air
PSI
Pickup
Shaft
Type
(4)
Spray
Rate
lb/h
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
H
2
Paral/
Cross
Inch
Set Air
PSI
430NS GE 731 111 28 500 60-70 -- -- 2 4 20.5 5 A 10
439NS G 730 80 20 500 60-65 -- -- 1 6 13.5 5 A 6
439NS-2 GP 733 111 17 400 75-80 -- -- 2 5-6 13.5 5 A 10
700 720 90 15 600 60-70 -- -- 2 6 13.5 5 A 19
443NS GH 732 90 20 500 70-80 -- -- 2 5-6 13.5 5 A 8
444 GH 732 90 15 500 64-70 -- -- 2(*) 4-6 13.5 5 A 25
445 GH 732 90 15
(8)
500 64-70 -- -- 2(*) 2-3 13.5 5 A 20
447NS GH 732 111 15
(8)
500 65-75 -- -- 4 6 13.5 5 A 25
449P GE 731 90 17 500 60-70 -- -- 2 6 13.5 5 A 18
450P GH 732 90 15 400 65-75 -- -- 2(*) 4 13.5 5 A 9
T2-7
Doc. 56347, Issue b
U.S. UNITS
NOTES:
clogging.
Nozzle Type Gas Flows
SCFH
(1)
Set
Amp.
(DC)
Voltage
Range
Distr.
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port Type
(3)
Spray
Dis-
tance
Inch
Carr.
Flows
SCFH
(7)
Set
Vibr.
Air
PSI
Pickup
Shaft
Type
(4)
Spray
Rate
lb/h
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
H
2
Paral/
Cross
Inch
Set Air
PSI
450NS GH 732 90 15 500 64-70 -- -- 2 4-7 13.5 5 A 9
GH 732 90 15 500 64-70 -- -- 2 6 13.5 5 A 10
707 727 90 15 800 50-60 -- -- 2 6 13.5 5 A 35
451 GH 732 90 20 500 70-80 -- -- 2 4-5 13.5 5 B 15
452 GH 732 90 15 500 60-70 -- -- 2 4-7 13.5 5 A 9
707 727 90 15 800 50-55 -- -- 6 6 13.5 5 A 35
453 GH 732 90 15 500 60-70 -- -- 2 5 10.5 5 A 8
461NS GH 732 90 20 500 70-80 -- -- 2 9 13.5 5 A 4
GH 732 90 20 500 70-80 -- -- 2 5-6 13.5 5 A 8
480NS GH 732 90 15 500 65-70 -- -- 2 6 13.5 5 B 9
707 727 90 15 800 50-60 -- -- 4 6 13.5 5 B 35
501 GP 733 111 17 400 75-80 -- -- 2 4-5 13.5 5 A 8.5
505 GH 732 79 15 400 65-75 Paral 70 2 4 13.5 5 A 10
600NS GP 733 212 6 500 65-75 Paral 70 2 3-3.5 26 5 A 3-3.5
601NS GP 733 212 6 500 65-75 Paral 75 2 3-4 20.5 5 A 3-3.5
GP 733 212 6 500 65-75 Paral 75 2 3-4 20.5 5 A 10
605NS GH 732 167 5 400 60-70 -- -- 2 3-3.5 13.5 5 B 7
610NS GH 732 167 15 400 75 -- -- 4
(2 Ports)
5 20.5 5 B 15
(7.5 2
Ports)
T2-8
Doc. 56347, Issue b
U.S. UNITS
NOTES:
clogging.
Nozzle
Type
Gas Flows
SCFH
(1)
Set
Amp.
(DC)
Voltage
Range
Distr.
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
Inch
Carr.
Flows
SCFH
(7)
Set
Vibr.
Air
PSI
Pickup
Shaft
Type
(4)
Spray
Rate
lb/h
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
H
2
Paral/
Cross
Inch
Set Air
PSI
700 GH 732 90 10 500 65 4 50 2 4 13.5 5 B 7
GP 733 140 17 500 80 Paral 50 2 6 13.5 5 B 7
GP 733 140 17 500 80 Paral 50 2
(2 Ports)
6 13.5 5 B 20
(10 2
Ports)
700F GE 731 140 17 500 70-75 4 50 2 4 13.5 5 B 7
GP 733 140 17 500 80 Paral 50 2 6 13.5 5 B 7
1123 GE 731 90 11 500 55-60 -- -- 2 4-6 13.5 5 B 12
2042 GH 732 100 20 500 60-65 -- -- 1 5 12 20 B 6-6.6
2043 GH 732 100 10 450 60-65 Paral 20-25 1 5 12 25 B 6
T2-9
Doc. 56347, Issue b
METRIC UNITS
NOTES:
(1) Set primary gas pressure to 5.1 bars. Set secondary gas pressure to 3.4 bars. Set air pressure to 5.8 bars. For soft start, set Argon
pressure to 3.3 bars. Install Argon (A) insulator in the gun. Set primary gas pressure with gas flowing.
hose and cable unit is 4.5 m long.) Adjust secondary flow to attain required voltage.
clogging.
(FMR) flow settings. Set argon carrier gas pressure to 4.1 bars.
Nozzle
Type
Gas Flows
NLPM
(1)
Set
Amp.
(DC)
Voltage
Range
DistrIbu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
mm
Carr.
Flows
NLPM
(7)
Set
Vibr.
Air
bar
Pickup
Shaft
Type
(4)
Spray
Rate
g/min
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
H
2
Paral/
Cross
mm
Set
Air
bar
34F GP 733 49 7.4 500 70-80 -- -- 2 152 6 0.3 A 64
41F-NS GE 731 49 2.6 500 50-60 102 2.4/3.4 2 51-64 6 0.3 A 72
707 727 49 4.8 600 45-50 102 2.4 2 51-64 6 1 A 151
43C-NS GH 732 49 2.2 400 55-65 -- -- 2 102-152 6 0.3 A 65
43F-NS GH 732 73 2.2 500 60-70 -- -- 2 102-152 6 0.3 A 121
43VF-NS GE 731 73 3.1 500 45-55 102 2.8 2 64 9 0.3 A 53
44 GH 732 49 2.2 500 55-65 -- -- 2 102-152 6 0.3 A 151
45C-NS GE 731 49 7.4 400 65-70 -- -- 2 114-140 6 0.3 A 53
45VF-NS GE 731 73 3.1 500 45-55 127 2.4/3.4 2 51-64 9 0.3 A 49
51NS GH 732 73 2.2 500 60-70 -- -- 2 102-152 6 0.3 A 110
51F-NS GE 731 73 8.3 450 65-75 -- -- 1 76-127 6 1.7 A 53
52C-NS GH 732 40 6.6 500 64-70 -- -- 1 102-152 6 0.3 A 76
54NS GH 732 73 4.4 500 70-75 -- -- 1 102-152 6 0.3 A 49
700 720 40 4.4 600 65-70 -- -- 2 102-152 6 0.3 A 60
55 GH 732 73 2.2 500 60-70 -- -- 1 102-150 6 0.3 A 113
56C-NS GH 732 40 4.4 500 55-65 -- -- 2 102-152 6 0.3 A 106
56F-NS GH 732 73 2.2 500 60-70 -- -- 2 102-152 6 0.3 A 113
57NS GH 732 37 6.6 500 60-70 114 2.4 2 64 6 0.3 A 45
58NS GH 732 37 6.6 500 60-70 114 2.4 2 64 6 0.3 A 45
T2-10
Doc. 56347, Issue b
METRIC UNITS
NOTES:
clogging.
Nozzle
Type
Gas Flows
NLPM
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
mm
Carr.
Flows
NLPM
(7)
Set
Vibr.
Air
bar
Pickup
Shaft
Type
(4)
Spray
Rate
g/min
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
H
2
Paral/
Cross
mm
Set Air
bar
63NS GE 731 49 7.4 700 60-70 -- -- 2 102 6 0.3 A 72
GH 732 39 6.6 500 64-70 -- -- 2 76-127 6 0.3 A 72
GH 732 39 6.6 500 64-70 -- -- 2 102 6 0.3 A 166
64 GH 732 39 6.6 400 65-70 Paral 3.4 2 102 6 0.3 A 76
GH 732 39 6.6 500 64-70 Paral 3.4 2 102 6 1 A 166
66F-NS GH 732 73 4.4 500 70-75 -- -- 2 102 6 1 A 45
68F-NS-1 GH 732 73 4.4 500 70-75 -- -- 2 102 6 1 A 45
70C-NS GH 732 73 4.4 500 60-70 -- -- 2 102 6 1 A 76
71NS GH 732 39 6.6 500 60-70 -- -- 2 76-127 6 0.3 A 129
GP 733 60 7.4 500 74-80 -- -- 2 64-89 6 0.3 A 30
71VF-NS GE 731 49 4.8 400 55-60 -- -- 2 64-102 6 1 B 60
73F-NS-1/
73F-NS-2
GE 731 78 3.9 400 50-55 -- -- 2 76 9 0.3 B 83
81NS GH 732 39 6.6 500 64-70 -- -- 2 76-127 6 0.3 A 181
GP 733 43 7.4 300 75-80 -- -- 2 76-127 6 0.3 A 38
81VF-NS GH 732 49 4.4 500 60-70 -- -- 2 51-64 6 1 A 42
GH 732 49 4.4 500 60-70 -- -- 2 64 6 1 A 144
700 720 39 6.6 600 60-70 -- -- 2 64 6 0.3 A 136
T2-11
Doc. 56347, Issue b
METRIC UNITS
NOTES:
clogging.
Nozzle
Type
Gas Flows
NLPM
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
mm
Carr.
Flows
NLPM
(7)
Set
Vibr.
Air
bar
Pickup
Shaft
Type
(4)
Spray
Rate
g/min
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
H
2
Paral/
Cross
mm
Set Air
bar
101NS GH 732 39 6.6 500 64-70 -- -- 2 51-102 6 1.7 A 53
101B-NS GH 732 39 11 500 70-80 -- -- 2 76-127 6 1.7 A 53
101SF GH 732 73 6.6 500 75-80 89 5.2 2 51 11.4 1.7 A 23
GP 733 64 8.3 500 75-80 89 5.2 2 51 11.4 1.7 A 23
700 720 39 6.6 600 65-75 89 5.2 2 76 11.4 1.7 A 53
102 GH 732 39 6.6 500 64-70 -- -- 2 76-102 6 1.7 A 53
105NS-1 GH 732 39 6.6 500 64-70 -- -- 2 51-102 6 1.7 A 42
105SF GH 732 73 6.6 500 75-80 89 5.2 2 51-64 11.4 1.7 A 23
GP 733 73 8.3 500 75-80 89 5.2 2 51-64 11.4 1.7 A 23
700 720 39 6.6 600 60-70 89 5.2 2 76 11.4 1.7 A 45
105SFP GH 732 73 4.4 500 75-80 89 5.2 2 64 11.4 1.7 A 23
700 720 39 6.6 600 60-70 89 5.2 2 64 11.4 1.7 A 45
GP 733 73 4.4 500 75-80 89 5.2 2 64 11.4 1.7 A 23
106 GH 732 35 6.6 500 64-70 -- -- 2 64 6 1.7 A 38
T2-12
Doc. 56347, Issue b
METRIC UNITS
NOTES:
clogging.
Nozzle
Type
Gas Flows
NLPM
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
mm
Carr.
Flows
NLPM
(7)
Set
Vibr.
Air
bar
Pickup
Shaft
Type
(4)
Spray
Rate
g/min
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
H
2
Paral/
Cross
mm
Set Air
bar
106F GH 732 35 6.6 500 60-70 152 3.4 2 64 6 1.7 A 38
111 GH 732 39 6.6 500 64-70 -- -- 2 76-102 6 0.3 A 45
130 GH 732 39 6.6 500 70-80 -- -- 2 102-127 6 1.7 A 38
130SF GH 732 35 8.8 500 60-70 89 3.4 2 64 9 1.7 A 23
131VF G 730 49 6.6 500 60-70 Paral 3.4 2 64-89 9 1.7 A 23
700 720 39 6.6 600 60-70 89 5.2 2 76 9 1.7 A 38
131VF GP 733 49 8.8 500 75-80 191 3.4 2 152 9 1.7 A 23
GP 733 49 8.8 500 75-80 Paral 3.4 2 64-89 9 1.7 A 23
136F GH 732 35 6.6 500 64-70 152 3.4 2 64 6 1.7 A 38
143 GE 731 37 7.5 600 60-70 76 4.8 2 76 6 1.4 A 38
GE 731 28 6.6 700 60-70 76 4.8 2 76 6 1.4 A 76
201NS GH 732 39 6.6 500 60-70 -- -- 2 51-102 6 1.7 A 45
201B-NS GH 732 39 6.6 500 60-75 -- -- 2 51-102 6 1.7 A 49
T2-13
Doc. 56347, Issue b
METRIC UNITS
NOTES:
clogging.
Nozzle
Type
Gas Flows
NLPM
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
mm
Carr.
Flows
NLPM
(7)
Set
Vibr.
Air
bar
Pickup
Shaft
Type
(4)
Spray
Rate
g/min
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
H
2
Paral/
Cross
mm
Set Air
bar
201B-NS-1 GH 732 39.4 10.9 500 70-80 -- -- 2 50-63 5.9 1.7 A 91
GH 732 39.4 10.9 500 70-80 -- -- 2 50-63 5.9 1.7 A 45
202NS GH 732 39.4 6.5 500 64-70 -- -- 2 63 5.9 1.7 A 91
GH 732 39.4 6.5 500 64-70 -- -- 2 63 5.9 1.7 A 45
204NS GH 732 39.4 6.5 600 64-70 -- -- 2 63 5.9 1.7 A 45
GH 732 39.4 6.5 600 64-70 -- -- 2 63 5.9 1.7 A 91
204B-NS G 730 39.4 6.5 500 60-70 -- -- 2 63 5.9 1.7 A 45
205NS GH 732 35 6.5 400 65-75 Paral 3.4 2 101 5.9 1.7 A 45
210NS-1 GH 732 35 6.5 500 64-70 -- -- 2 76 5.9 1.7 A 38
303NS-1 GH 732 39.4 6.5 500 64-70 -- -- 2 101 5.9 1.7 A 45
311NS GH 732 48.6 6.5 500 60-70 Paral 5.1 6 101 5.9 1.7 A 60
313NS GH 732 92.8 4.3 500 75-85 -- -- 1 127 8.9 1.7 A 60
320NS GH 732 92.8 2.6 500 70-80 Paral 1.7-2 1 152 7.8 1.7 A 53
350NS GH 731 48.6 7.4 500 65-70 Paral 4.8 1 101 5.9 0.3 A 76
404NS GH 732 48.6 7.4 500 64-70 -- -- 1 101-
152
5.9 0.3 A 75
410NS GH 732 39.4 6.5 500 64-70 -- -- 1 76-
127
5.9 0.3 A 38
T2-14
Doc. 56347, Issue b
METRIC UNITS
NOTES:
clogging.
(8) Secondary gas flow can be adjusted 2.1 NLPM in order to achieve desired voltage range. DO NOT REDUCE secondary gas flow
to zero, NOR GO ABOVE 10.9 NLPM.
Nozzle
Type
Gas Flows
NLPM
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
mm
Carr.
Flows
NLPM
(7)
Set
Vibr.
Air
bar
Pickup
Shaft
Type
(4)
Spray
Rate
g/min
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
H
2
Paral/
Cross
mm
Set Air
bar
430NS GE 731 48.6 12.2 500 60-70 -- -- 2 101 9 0.3 A 76
439NS G 730 35 8.7 500 60-65 -- -- 1 152 6 0.3 A 45
439NS-2 GP 733 48.6 7.4 400 75-80 -- -- 2 127-
152
6 0.3 A 76
700 720 39.4 6.5 600 60-70 -- -- 2 152 6 0.3 A 144
443NS GH 732 39.4 8.7 500 70-80 -- -- 2 127-
152
6 0.3 A 60
444 GH 732 39.4 6.5 500 64-70 -- -- 2(*) 101-
152
6 0.3 A 190
445 GH 732 39.4 6.5
(8)
500 64-70 -- -- 2(*) 50-76 6 0.3 A 151
447NS GH 732 48.6 6.5
(8)
500 65-75 -- -- 4 152 6 0.3 A 190
449P GE 731 39.4 7.4 500 60-70 -- -- 2 152 6 0.3 A 60
450P GH 732 39.4 6.5 400 65-75 -- -- 2(*) 101 6 0.3 A 68
T2-15
Doc. 56347, Issue b
METRIC UNITS
NOTES:
clogging.
Nozzle
Type
Gas Flows
NLPM
(1)
Set
Amp.
(DC)
Voltage
Range
Distr.
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
mm
Carr.
Flows
NLPM
(7)
Set
Vibr.
Air
bar
Pickup
Shaft
Type
(4)
Spray
Rate
g/min
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
H
2
Paral/
Cross
mm
Set Air
bar
450NS GH 732 39 6.6 500 64-70 -- -- 2 102-
178
6 0.3 A 68
GH 732 39 6.6 500 64-70 -- -- 2 152 6 0.3 A 76
707 727 39 6.6 800 64-70 -- -- 2 152 6 0.3 A 93
451 GH 732 39 8.8 500 50-60 -- -- 2 102-
127
6 0.3 B 113
452 GH 732 39 6.6 500 70-80 -- -- 2 102-
178
6 0.3 A 68
707 727 39 6.6 800 60-70 -- -- 6 152 6 0.3 A 265
453 GH 732 39 6.6 500 50-55 -- -- 2 127 4.6 0.3 A 60
461NS GH 732 39 8.8 500 60-70 -- -- 2 229 6 0.3 A 30
GH 732 39 8.8 500 70-80 -- -- 2 127-
152
6 0.3 A 60
480NS GH 732 39 6.6 500 70-80 -- -- 2 152 6 0.3 B 68
707 727 39 6.6 800 65-70 -- -- 4 152 6 0.3 B 265
501 GP 733 49 7.4 400 50-60 -- -- 2 102-
127
6 0.3 A 64
505 GH 732 35 6.6 400 75-80 Paral 4.8 2 102 6 0.3 A 76
600NS GP 733 93 2.6 500 65-75 Paral 4.8 2 76-89 11.4 0.3 A 23-26
601NS GP 733 93 2.6 500 65-75 Paral 5.2 2 76-102 9 0.3 A 23-26
GP 733 93 2.6 500 65-75 Paral 5.2 2 76-102 9 0.3 A 76
605NS GH 732 73 2.2 400 60-70 -- -- 2 76-89 6 0.3 B 53
610NS GH 732 73 6.6 400 75 -- -- 4
(2 Ports)
127 9 0.3 B 114
(57 2
Ports)
T2-16
Doc. 56347, Issue b
METRIC UNITS
NOTES:
clogging.
Nozzle
Type
Gas Flows
NLPM
(1)
Set
Amp.
(DC)
Voltage
Range
Distr.
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
mm
Carr.
Flows
NLPM
(7)
Set
Vibr.
Air
bar
Pickup
Shaft
Type
(4)
Spray
Rate
g/min
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
H
2
Paral/
Cross
mm
Set Air
bar
700 GH 732 39 4.4 500 65 102 3.4 2 102 6 0.3 B 53
GP 733 61 7.4 500 80 Paral 3.4 2 152 6 0.3 B 53
GP 733 61 7.4 500 80 Paral 3.4 2
(2 Ports)
152 6 0.3 B 152
(76 2
Ports)
700F GE 731 61 7.4 500 70-75 102 3.4 2 102 6 0.3 B 53
GP 733 61 7.4 500 80 Paral 3.4 2 152 6 0.3 B 53
1123 GP 731 39 4.8 500 55-60 -- -- 2 102-
152
6 0.3 B 91
2042 GH 732 44 8.8 500 60-65 -- -- 1 127 5.25 1.4 B 45-50
2043 GH 732 44 4.4 450 60-65 Paral 1.4-1.7 1 127 5.25 1.7 B 45
TABLE 3 ARGON / HELIUM
T3-1
Doc. 56347, Issue b
U.S. UNITS
NOTES:
clogging.
(8) Set power level to 58 kW by varying the secondary gas flow 15 SCFH. DO NOT EXCEED THIS LEVEL.
Nozzle
Type
Gas Flows
SCFH
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
Inch
Carr.
Flows
SCFH
(7)
Set
Vibr.
Air
PSI
Pickup
Shaft
Type
(4)
Spray
Rate
lb/h
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
He
Paral/
Cross
Inch
Set Air
PSI
45C-NS GP 733 39 176 700 42-47 -- -- 3 3 13.5 5 A 4
63NS GP 733 35 109 750 45-50 -- -- 3 5 13.5 5 A 3.5
71NS GP 733 35 137 900 40-45 -- -- 1 5 17.5 5 A 15
71VF-NS GP 733 35 137 500 45-50 -- -- 3 2.5-4 13.5 5 B 4
704 724 224 88 600 60-70 -- -- 5 2.5 20.5 5 B 6
72F-NS GP 733 180 140 500 70-75 -- -- 3 2.5-3.5 26 5 B 8
73F-NS-1/
73F-NS-2
704 724 224 53 1000 58
(8)
-- -- 5 3.5 20.5 5 B 6
73SF-NS 704 724 258 53 600 60-70 -- -- 5 2.5 20.5 5 B 6
81NS GP 733 35 137 900 40-45 -- -- 3 4 20.5 5 A 2.5
81VF-NS GP 733 35 137 800 40-50 3 35-50 3 2-2.5 20.5 5 A 5.5
82VF-NS GE 731 50 62 800 40-45 Paral 50 5 2 13.5 5 A 6
404NS GH 732 30 137 750 42-47 -- -- 3 6 20.5 5 A 3
450NS GH 732 30 137 500 42-47 -- -- 3 4 20.5 5 A 3
600NS GP 733 134 106 500 55-60 Paral 75 2 3-3.5 26 5 A 3-3.5
601NS GP 733 167 26 500 45-50 Paral 75 2 3-4 20.5 5 A 3-3.5
605NS GH 732 111 88 500 45-50 -- -- 2 3-3.5 13.5 5 B 7
TABLE 3 ARGON / HELIUM
METRIC UNITS
NOTES:
(1) Set primary gas pressure to 5.1 bars. Set secondary gas pressure to 3.4 bars. Set air pressure to 5.8 bars. (For soft start, set Argon
pressure to 3.3 bars.) Install Argon (A) insulator in the gun. (Set primary gas pressure with gas flowing.)
hose package is 4.5 m long.) Adjust secondary flow to attain required voltage.
clogging.
(8) Set power level to 58 kW by varying the secondary gas flow 6.5 NLPM. DO NOT EXCEED THIS LEVEL.
NLPM
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port Type
(3)
Spray
Dis-
tance
mm
Carr.
Flows
NLPM
(7)
Set
Vibr.
Air
bar
Pickup
Shaft
Type
(4)
Spray
Rate
g/min
(5)
7MB
Gun
9MB
Gun
Prim.
Ar
Sec.
He
Paral/
Cross
mm
Set Air
bar
45C-NS GP 733 17 7.7 700 42-47 -- -- 3 76 6 0.3 A 4
63NS GP 733 15 48 750 45-50 -- -- 3 127 6 0.3 A 3.5
71NS GP 733 15 60 900 40-45 -- -- 1 127 7.7 0.3 A 15
71VF-NS GP 733 15 60 500 45-50 -- -- 3 64-102 6 0.3 B 4
704 724 98 39 600 60-70 -- -- 5 64 9 0.3 B 6
72F-NS GP 733 79 61 500 70-75 -- -- 3 64-89 11.4 0.3 B 8
73F-NS-1/
73F-NS-2
704 724 98 23 1000 58
(8)
-- -- 5 89 9 0.3 B 6
73SF-NS 704 724 113 23 600 60-70 -- -- 5 64 9 0.3 B 6
81NS GP 733 15 60 900 40-45 -- -- 3 102 9 0.3 A 2.5
81VF-NS GP 733 15 60 800 40-50 76 2.4-3.4 3 51-64 9 0.3 A 5.5
82VF-NS GE 731 22 27 800 40-45 Paral 3.4 5 51 6 0.3 A 6
404NS GH 732 13 60 750 42-47 -- -- 3 152 9 0.3 A 3
450NS GH 732 13 60 500 42-47 -- -- 3 102 9 0.3 A 3
600NS GP 733 59 46 500 55-60 Paral 5.2 2 76-89 11.4 0.3 A 3-3.5
601NS GP 733 73 11 500 45-50 Paral 5.2 2 76-102 9 0.3 A 3-3.5
605NS GH 732 49 39 500 45-50 -- -- 2 76-89 6 0.3 B 7
TABLE 4 PURE NITROGEN
T4-1
Doc. 56347, Issue b
U.S. UNITS
NOTES:
(1) Set primary gas pressure to 48 psi. Set air pressure to 85 psi. Install Nitrogen (N) insulator in the gun. (Set primary gas pressure
with gas flowing.)
reads 3 to 10 volts lower than the distribution unit voltage. Distribution unit voltage varies with cable lengths. (The standard 7MH
(4 )Pickup shaft selection depends on feed rate. Refer to powder feeder manual for selection procedure.
clogging.
settings. Set nitrogen carrier gas pressure to 40 psi.
Nozzle
Type
Gas Flows
SCFH
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
Inch
Carr.
Flows
SCFH
(7)
Set
Vibr.
Air
PSI
Pickup
Shaft
Type
(4)
Spray
Rate
lb/h
(5)
7MB
Gun
9MB
Gun
Prim.
N
2
Sec. Paral/
Cross
Inch
Set Air
PSI
44 707 727 75 -- 400 65-70 -- -- 1 4-6 14 5 A 25
51NS 707 727 150 -- 600 65-70 -- -- 2 4-6 14 5 A 25
54NS 707 727 150 -- 600 65-70 -- -- 1(*) 4-6 14 5 A 15
63NS 700 720 150 -- 600 65-70 -- -- 1 6 14 5 A 22
101NS 700 720 90 -- 700 65-70 -- -- 2 2-4 14 25 A 15
101SF 700 720 120 -- 700 60-70 -- -- 2 2.5 27 25 A 6
105NS 700 720 90 -- 700 65-70 -- -- 2 2.5 14 25 A 15
105SF 700 720 120 -- 700 60-70 -- -- 2 2.5 27 25 A 6
105SFP 700 720 120 -- 700 60-70 6.5 50 2 2.5 27 25 A 6
106F 700 720 90 -- 700 65-70 6 50 2 2.5 9 25 A 15
130 700 720 71 -- 700 60-70 -- -- 2 4 9 25 A 10
130SF 700 720 120 -- 700 60-70 Paral 50 2 2.5 21.5 25 A 5
707 727 90 -- 600 65-70 Paral 50 2 2.5 20.5 25 A 3
131VF 707 727 90 -- 600 65-70 Paral 50 2 2.5 20.5 25 A 3
U.S. UNITS
NOTES:
(1) Set primary gas pressure to 48 psi. Set air pressure to 85 psi. Install Nitrogen (N) insulator in the gun. (Set primary gas pressure
with gas flowing.)
clogging.
settings. Set nitrogen carrier gas pressure to 40 psi.
Nozzle
Type
Gas Flows
SCFH
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
Inch
Carr.
Flows
SCFH
(7)
Set
Vibr.
Air
PSI
Pickup
Shaft
Type
(4)
Spray
Rate
lb/h
(5)
7MB
Gun
9MB
Gun
Prim.
N
2
Sec. Paral/
Cross
Inch
Set Air
PSI
136F 700 720 88 -- 700 65-70 6 50 2 2.5 14 25 A 15
202NS 700 720 71 -- 700 60-70 -- -- 2 3-4 14 5 A 15
442 707 727 88 -- 500 65-70 -- -- 2 10 14 5 A 25
707 727 88 -- 600 60-70 -- -- 2 4-6 14 5 A 25
444 707 727 88 -- 600 60-70 -- -- 2 4-6 14 5 A 25
445 707 727 175 -- 400 60-70 -- -- 2 4-6 14 5 A 25
447NS 707 727 88 -- 600 60-70 -- -- 2 4-6 14 5 A 25
450NS 700 720 71 -- 700 60-70 -- -- 6 4-6 14 5 A 35
700 720 120 -- 600 65-75 -- -- 2 6 12 5 A 35
450P 700 720 118 -- 600 65-75 -- -- 2 6 14 5 A 35
452 700 720 118 -- 600 65-75 -- -- 6 6 14 5 A 35
501 707 727 160 -- 650 60-65 -- -- 2 4-5 14 5 A 25
505 700 720 148 -- 600 65-75 Paral 75 2 4 14 5 A 20
700 G 730 65 -- 500 65 Paral 50 2 4 14 5 B 10
1123 GE 731 88 -- 500 60-70 -- -- 5 4-6 14 5 B 13
T4-3
Doc. 56347, Issue b
METRIC UNITS
NOTES:
(1) Set primary gas pressure to 3.3 bars. Set air pressure to 5.8 bars. Install Nitrogen (N) insulator in the gun. (Set primary gas pressure
with gas flowing.)
clogging.
settings. Set nitrogen carrier gas pressure to 2.7 bars.
NLPM
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port Type
(3)
Spray
Dis-
tance
mm
Carr.
Flow
NLPM
(7)
Set
Vibr.
Air
bar
Pickup
Shaft
Type
(4)
Spray
Rate
g/min
(5)
7MB
Gun
9MB
Gun
Prim.
N
2
Sec. Paral/
Cross
mm
Set Air
bar
44 707 727 33 -- 400 65-70 -- -- 1 102-
152
6 0.3 A 189
51NS 707 727 66 -- 600 60-70 -- -- 2 102-
152
6 0.3 A 189
54NS 707 727 66 -- 600 65-70 -- -- 1(*) 102-
152
6 0.3 A 113
63NS 700 720 66 -- 600 60-70 -- -- 1 152 6 0.3 A 166
101NS 700 720 39 -- 700 60-70 -- -- 2 51-102 6 1.7 A 113
101SF 700 720 53 -- 700 60-70 -- -- 2 64 11.8 1.7 A 45
105NS 700 720 39 -- 700 60-70 -- -- 2 64 6 1.7 A 113
105SF 700 720 53 -- 700 60-70 -- -- 2 64 11.8 1.7 A 45
105SFP 700 720 53 -- 700 65-75 165 3.4 2 64 11.8 1.7 A 45
106F 700 720 39 -- 700 65-75 152 3.4 2 64 3.9 1.7 A 113
130 700 720 31 -- 700 60-65 -- -- 2 102 3.9 1.7 A 76
130SF 700 720 53 -- 700 65-75 Paral 3.4 2 64 9.4 1.7 A 38
707 727 39 -- 600 65 Paral 3.4 2 64 9 1.7 A 23
131VF 707 727 39 -- 600 60-70 Paral 3.4 2 64 9 1.7 A 23
METRIC UNITS
NOTES:
(1) Set primary gas pressure to 3.3 bars. Set air pressure to 5.8 bars. Install Nitrogen (N) insulator in the gun. (Set primary gas pressure
with gas flowing.)
clogging.
settings. Set nitrogen carrier gas pressure to 2.7 bars.
NLPM
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port Type
(3)
Spray
Dis-
tance
mm
Carr.
Flow
NLPM
(7)
Set
Vibr.
Air
bar
Pickup
Shaft
Type
(4)
Spray
Rate
g/min
(5)
7MB
Gun
9MB
Gun
Prim.
N
2
Sec. Paral/
Cross
mm
Set Air
bar
136F 700 720 39 -- 700 65-70 152 3.4 2 64 6.1 1.7 A 113
202NS 700 720 31 -- 700 60-70 -- -- 2 76-102 6.1 0.3 A 113
442 707 727 39 -- 500 65-70 -- -- 2 254 6.1 0.3 A 189
707 727 39 -- 600 60-70 -- -- 2 102-
152
6.1 0.3 A 189
444 707 727 39 -- 600 60-70 -- -- 2 102-
152
6.1 0.3 A 189
445 707 727 77 -- 400 60-70 -- -- 2 102-
152
6.1 0.3 A 189
447NS 707 727 39 -- 600 60-70 -- -- 2 102-
152
6.1 0.3 A 189
450NS 700 720 31 -- 700 60-70 -- -- 6 102-
152
6.1 0.3 A 265
700 720 53 -- 600 65-75 -- -- 2 152 5.3 0.3 A 265
450P 700 720 52 -- 600 65-75 -- -- 2 152 6.1 0.3 A 265
452 700 720 52 -- 600 65-75 -- -- 6 152 6.1 0.3 A 265
501 707 727 70 -- 650 60-65 -- -- 2 102-
127
6.1 0.3 A 189
505 700 720 65 -- 600 65-75 Paral 5.2 2 102 6.1 0.3 A 151
700 G 730 28 -- 500 65 Paral 3.4 2 102 6.1 0.3 B 76
1123 GE 731 39 -- 500 60-70 -- -- 5 102-
152
6.1 0.3 B 98
TABLE 5 NITROGEN / HYDROGEN
T5-1
Doc. 56347, Issue b
U.S. UNITS
NOTES:
(1) Set primary gas pressure to 48 psi. Set secondary gas pressure to 50 psi. Set air pressure to 85 psi. Install Nitrogen (N) insulator in
the gun. Set primary gas pressure with gas flowing.
clogging.
(FMR) flow settings. Set nitrogen carrier gas pressure to 40 psi.
Nozzle
Type
Gas Flows
SCFH
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
Inch
Carr.
Flows
SCFH
(7)
Set
Vibr.
Air
PSI
Pickup
Shaft
Type
(4)
Spray
Rate
lb/h
(5)
7MB
Gun
9MB
Gun
Prim.
N
2
Sec.
H
2
Paral/
Cross
Inch
Set Air
PSI
31C-NS G 730 100 15 400 70-80 -- -- 1 4-6 12 5 A 18
32C G 730 100 15 400 70-80 -- -- 1 4-6 12 5 A 18
34F GE 731 150 18 400 75-85 -- -- 2 6 12 5 A 9
34FP G 730 100 15 400 70-80 -- -- 1 4-6 12 5 A 16
41C G 730 100 15 400 70-80 -- -- 1 4-6 12 5 A 14.5
42C G 730 100 15 400 70-80 -- -- 1 4-6 12 5 A 17
43C-NS G 730 100 15 400 70-80 -- -- 1 4-6 12 5 A 19
43F-NS G 730 100 15 400 70-80 -- -- 1 4-6 12 5 A 16
44 G 730 100 15 400 70-80 -- -- 1 4-6 12 5 A 20
45C-NS G 730 100 15 400 70-80 -- -- 1 4.5-5.5 12 5 A 15
51NS G 730 150 5 400 65-75 -- -- 1 4-6 12 5 A 18.5
51F-NS GE 731 150 13 350 65-75 -- -- 1 3-5 12 5 A 8
52C-NS G 730 125 15 500 70-80 -- -- 1 4-6 12 5 A 10
54NS-1 G 730 150 10 400 65-70 -- -- 1(*) 4-6 12 5 A 6.5
55 G 730 150 10 400 70-80 -- -- 1 4-6 12 5 A 15
56C-NS G 730 100 5 500 65-75 -- -- 2 4-6 12 5 A 16
56F-NS G 730 150 10 400 65-70 -- -- 2 4-6 12 5 A 15
57NS GE 731 100 17 450 75-85 4.5 40 2 2.5 12 5 A 6
58NS GE 731 100 17 450 75-85 4.5 40 2 2.5 12 5 A 6
U.S. UNITS
NOTES:
clogging.
Nozzle
Type
Gas Flows
SCFH
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
Inch
Carr.
Flows
SCFH
(7)
Set
Vibr.
Air
PSI
Pickup
Shaft
Type
(4)
Spray
Rate
lb/h
(5)
7MB
Gun
9MB
Gun
Prim.
N
2
Sec.
H
2
Paral/
Cross
Inch
Set Air
PSI
63-NS G 730 100 15 400 70-80 -- -- 1 3-5 12 5 A 9.5
G 730 100 15 400 70-60 -- -- 1 4 12 5 A 22
64 GE 731 100 17 400 75-85 Paral 50 2 4 12 5 A 10
G 730 75 15 400 74-80 Paral 50 2 4 12 5 A 22
70C-NS G 730 75 15 500 74-80 -- -- 1 3-5 12 5 A 14
81NS G 730 75 15 500 74-80 -- -- 2 3-5 12 5 A 15
81VF-NS GE 731 150 6 500 70-80 4 35-50 2 2-2.5 18 5 A 5.5
GE 731 150 6 500 70-80 4 35-50 2 2.5 18 5 A 17.5
101NS G 730 75 15 500 74-80 -- -- 2 2-4 12 25 A 7
G 730 75 15 500 74-80 -- -- 2 2-4 14 25 A 12
101B-NS G 730 75 15 500 74-80 -- -- 2 3-5 12 25 A 7
102 G 730 75 15 500 74-80 -- -- 2 3-4 12 25 A 7
105NS/ G 730 75 15 500 74-80 -- -- 2 2-4 12 25 A 5.5
105NS-1 G 730 75 15 500 74-80 -- -- 2 2-4 14.5 25 A 10
106 G 730 75 15 500 74-80 -- -- 2 2.5 12 25 A 9
106F G 730 75 15 500 74-80 6 50 2 2.5 12 25 A 10
T5-3
Doc. 56347, Issue b
U.S. UNITS
NOTES:
clogging.
Nozzle
Type
Gas Flows
SCFH
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
Inch
Carr.
Flows
SCFH
(7)
Set
Vibr.
Air
PSI
Pickup
Shaft
Type
(4)
Spray
Rate
lb/h
(5)
7MB
Gun
9MB
Gun
Prim.
N
2
Sec.
H
2
Paral/
Cross
Inch
Set Air
PSI
111 G 730 75 15 500 74-80 -- -- 2 3-4 12 5 A 6
130 G 730 75 15 500 74-80 -- -- 2 4-5 12 25 A 5
130SF G 730 100 15 500 74-80 3.5 50 2 2.5 18 25 A 3
131VF G 730 100 15 500 74-80 Paral 50 2 2.5-3.5 18 25 A 3
GE 731 75 17 500 74-80 Paral 50 2 2.5-3.5 18 25 A 3
136F G 730 75 15 500 74-80 6.5 50 2 3 12 25 A 9
136CP G 730 75 15 500 74-80 6.5 50 2 3 12 25 A 8.5
201NS G 730 75 15 500 74-80 -- -- 2 2-4 12 25 A 12
201B-NS G 730 75 15 500 75-80 -- -- 2 2-4 12 25 A 12
G 730 75 15 500 75-80 -- -- 2 2-4 14 25 A 16
201B-NS-1 G 730 75 15 500 74-80 -- -- 2 2-2.5 12 25 A 6
G 730 75 15 500 74-80 -- -- 2 2-2.5 12 25 A 12
202-NS G 730 75 15 500 74-80 -- -- 2 2.5 12 25 A 6
G 730 75 15 500 74-80 -- -- 2 2.5 12 25 A 12
204-NS G 730 75 15 500 74-80 -- -- 2 2.5 12 25 A 6
G 730 75 15 500 74-80 -- -- 2 2.5 12 25 A 12
204B-NS G 730 75 15 500 74-80 -- -- 2 2.5 12 25 A 6
G 730 75 15 500 74-80 -- -- 2 2.5 12 25 A 12
U.S.UNITS
NOTES:
clogging.
(8) Secondary gas flow can be varied 5 SCFH to achieve desired voltage range. DO NOT REDUCE secondary gas flow to zero,
NOR GO ABOVE 25 SCFH.
Nozzle
Type
Gas Flows
SCFH
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
Inch
Carr.
Flows
SCFH
(7)
Set
Vibr.
Air
PSI
Pickup
Shaft
Type
(4)
Spray
Rate
lb/h
(5)
7MB
Gun
9MB
Gun
Prim.
N
2
Sec.
H
2
Paral/
Cross
Inch
Set Air
PSI
205NS G 730 75 15 500 75-80 -- -- 2 4-5 12 25 A 6
210NS-1 G 730 75 15 500 74-80 -- -- 2 4 12 25 A 11
212F-NS G 730 75 15 500 74-80 -- -- 2 7 12 25 A 6
303NS-1 GE 731 75 17 500 74-80 -- -- 2 5 12 5 A 8
350NS GE 731 100 17 400 75-85 Paral 70 1 4 12 5 A 12
404NS G 730 75 15
(8)
500 74-80 -- -- 1 4-6 12 5 A 15
410NS G 730 75 15 500 74-80 -- -- 1 3-5 12 5 A 8
430NS GE 731 150 13 400 75-85 -- -- 2 4 18 5 A 10
439NS GE 731 75 17 500 74-80 -- -- 2 6-7 12 5 A 15
439NS-2 GE 731 75 17 500 74-80 -- -- 1 6-7 12 5 A 15
443NS G 730 150 15 500 74-80 -- -- 2 5-6 12 5 A 8
445 G 730 150 15 500 74-80 -- -- 1 4-6 12 5 A 20
T5-5
Doc. 56347, Issue b
U.S. UNITS
NOTES:
clogging.
(8) Secondary gas flow can be varied 5 SCFH to achieve desired voltage range. DO NOT REDUCE secondary gas flow to zero,
NOR GO ABOVE 25 SCFH.
Nozzle
Type
Gas Flows
SCFH
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port
Type
(3)
Spray
Dis-
tance
Inch
Carr.
Flows
SCFH
(7)
Set
Vibr.
Air
PSI
Pickup
Shaft
Type
(4)
Spray
Rate
lb/h
(5)
7MB
Gun
9MB
Gun
Prim.
N
2
Sec.
H
2
Paral/
Cross
Inch
Set Air
PSI
447NS G 730 150 10
(8)
500 70-80 -- -- 2 4-6 12 5 A 9
450NS G 730 150 10 500 70-80 -- -- 2 4-7 12 5 A 9
450P G 730 150 10 400 65-75 -- -- 2(*) 4 12 5 A 9
451 G 730 100 15 500 74-80 -- -- 1 4-5 12 5 A 16
452 G 730 150 10 500 75-80 -- -- 2 4-7 12 5 A 9
453 G 730 150 10 500 70-80 -- -- 2 5 12 5 A 8
GE 731 75 11 500 75-85 -- -- 6 5.5 12 5 A 15
461NS G 730 150 15 500 75-80 -- -- 2 5-6 12 5 A 8
501 GE 731 150 19 400 75-85 -- -- 2 4-5 12 5 A 9.5
505 G 730 100 15 350 70-80 Paral 70 2 4 12 5 A 12
GE 731 100 17 400 70-80 Paral 70 2 4.5 12 5 A 12
605NS GE 731 150 6 350 65-75 -- -- 2 3-3.5 12 5 A 10
700F GE 731 100 17 400 85 4 70 2 4 12 5 A 7
METRIC UNITS
NOTES:
(1) Set primary gas pressure to 3.3 bars. Set secondary gas pressure to 3.4 bars. Set air pressure to 5.8 bars. Install Nitrogen (N)
insulator in the gun. Set primary gas pressure with gas flowing.
clogging.
(FMR) flow settings. Set nitrogen carrier gas pressure to 2.7 bars.
NLPM
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port Type
(3)
Spray
Dis-
tance
mm
Carr.
Flows
NLPM
(7)
Set
Vibr.
Air
bar
Pickup
Shaft
Type (4)
Spray
Rate
g/min
(5)
7MB
Gun
9MB
Gun
Prim.
N
2
Sec.
H
2
Paral/
Cross
mm
Set Air
bar
31C-NS G 730 44 6.6 400 70-80 -- -- 1 102-152 5.3 0.3 A 136
32C G 730 44 6.6 400 70-80 -- -- 1 102-152 5.3 0.3 A 136
34F GE 731 66 7.9 400 75-85 -- -- 2 152 5.3 0.3 A 68
34FP G 730 44 6.6 400 70-80 -- -- 1 102-152 5.3 0.3 A 121
41C G 730 44 6.6 400 70-80 -- -- 1 102-152 5.3 0.3 A 110
42C G 730 44 6.6 400 70-80 -- -- 1 102-152 5.3 0.3 A 120
43C-NS G 730 44 6.6 400 70-80 -- -- 1 102-152 5.3 0.3 A 144
43F-NS G 730 44 6.6 400 70-80 -- -- 1 102-152 5.3 0.3 A 121
44 G 730 44 6.6 400 70-80 -- -- 1 102-152 5.3 0.3 A 151
45C-NS G 730 44 6.6 400 70-80 -- -- 1 114-140 5.3 0.3 A 113
51NS G 730 66 2.2 400 65-75 -- -- 1 102-152 5.3 0.3 A 140
51F-NS GE 731 66 5.7 350 65-75 -- -- 1 76-127 5.3 0.3 A 60
52C-NS G 730 55 6.6 500 70-80 -- -- 1 102-152 5.3 0.3 A 76
54NS-1 G 730 66 4.4 400 65-70 -- -- 1(*) 102-152 5.3 0.3 A 49
55 G 730 66 4.4 400 70-80 -- -- 1 102-152 5.3 0.3 A 113
56C-NS G 730 44 2.2 500 65-75 -- -- 2 102-152 5.3 0.3 A 121
56F-NS G 730 66 4.4 400 65-70 -- -- 2 102-152 5.3 0.3 A 113
57NS GE 731 44 7.4 450 75-85 114 2.8 2 64 5.3 0.3 A 45
58NS GE 731 44 7.4 450 75-85 114 2.8 2 64 5.3 0.3 A 45
T5-7
Doc. 56347, Issue b
METRIC UNITS
NOTES:
clogging.
NLPM
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port Type
(3)
Spray
Dis-
tance
mm
Carr.
Flows
NLPM
(7)
Set
Vibr.
Air
bar
Pickup
Shaft
Type (4)
Spray
Rate
g/min
(5)
7MB
Gun
9MB
Gun
Prim.
N
2
Sec.
H
2
Paral/
Cross
mm
Set Air
bar
63-NS G 730 44 6.6 400 70-80 -- -- 1 76-127 5.3 0.3 A 72
G 730 44 6.6 400 70-60 -- -- 1 102 5.3 0.3 A 166
64 GE 731 44 7.4 400 75-85 Paral 3.4 2 102 5.3 0.3 A 72
G 730 33 6.6 400 74-80 Paral 3.4 2 102 5.3 0.3 A 166
70C-NS G 730 33 6.6 500 74-80 -- -- 1 76-127 5.3 0.3 A 106
81NS G 730 33 6.6 500 74-80 -- -- 2 76-127 5.3 0.3 A 113
81VF-NS GE 731 66 2.6 500 70-80 102 2.4-3.4 2 51-64 51-64 0.3 A 42
GE 731 66 2.6 500 70-80 102 2.4-3.4 2 64 7.9 0.3 A 132
101NS G 730 33 6.6 500 74-80 -- -- 2 51-102 5.3 1.7 A 53
G 730 33 6.6 500 74-80 -- -- 2 51-102 6.1 1.7 A 91
101B-NS G 730 33 6.6 500 74-80 -- -- 2 76-127 5.3 1.7 A 53
102 G 730 33 6.6 500 74-80 -- -- 2 76-102 5.3 1.7 A 53
105NS/ G 730 33 6.6 500 74-80 -- -- 2 51-102 5.3 1.7 A 42
105NS-1 G 730 33 6.6 500 74-80 -- -- 2 51-102 6.4 1.7 A 76
106 G 730 33 6.6 500 74-80 -- -- 2 64 5.3 1.7 A 68
106F G 730 33 6.6 500 74-80 152 3.4 2 64 5.3 1.7 A 76
METRIC UNITS
NOTES:
clogging.
NLPM
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port Type
(3)
Spray
Dis-
tance
mm
Carr.
Flows
NLPM
(7)
Set
Vibr.
Air
bar
Pickup
Shaft
Type (4)
Spray
Rate
g/min
(5)
7MB
Gun
9MB
Gun
Prim.
N
2
Sec.
H
2
Paral/
Cross
mm
Set Air
bar
111 G 730 33 6.6 500 74-80 -- -- 2 76-102 5.3 0.3 A 45
130 G 730 33 6.6 500 74-80 -- -- 2 102-127 5.3 1.7 A 38
130SF G 730 44 6.6 500 74-80 89 3.4 2 64 7.9 1.7 A 23
131VF G 730 44 6.6 500 74-80 Paral 3.4 2 64-89 7.9 1.7 A 23
GE 731 33 7.4 500 74-80 Paral 3.4 2 64-89 7.9 1.7 A 23
136F G 730 33 6.6 500 74-80 165 3.4 2 76 5.3 1.7 A 68
136CP G 730 33 6.6 500 74-80 165 3.4 2 76 5.3 1.7 A 64
201NS G 730 33 6.6 500 74-80 -- -- 2 51-102 5.3 1.7 A 91
201B-NS G 730 33 6.6 500 75-80 -- -- 2 51-102 5.3 1.7 A 91
G 730 33 6.6 500 75-80 -- -- 2 51-102 6.1 1.7 A 121
201B-NS-1 G 730 33 6.6 500 74-80 -- -- 2 51-64 5.3 1.7 A 45
G 730 33 6.6 500 74-80 -- -- 2 51-64 5.3 1.7 A 91
202-NS G 730 33 6.6 500 74-80 -- -- 2 64 5.3 1.7 A 45
G 730 33 6.6 500 74-80 -- -- 2 64 5.3 1.7 A 91
204-NS G 730 33 6.6 500 74-80 -- -- 2 64 5.3 1.7 A 45
G 730 33 6.6 500 74-80 -- -- 2 64 5.3 1.7 A 91
204B-NS G 730 33 6.6 500 74-80 -- -- 2 64 5.3 1.7 A 45
G 730 33 6.6 500 74-80 -- -- 2 64 5.3 1.7 A 91
T5-9
Doc. 56347, Issue b
METRIC UNITS
NOTES:
hose and cable unit is 4.5 bars long.) Adjust secondary flow to attain required voltage.
clogging.
(8) Secondary gas flow can be varied 2.1 NLPM to achieve desired voltage range. DO NOT REDUCE secondary gas flow to zero,
NOR GO ABOVE 10.9 NLPM.
NLPM
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port Type
(3)
Spray
Dis-
tance
mm
Carr.
Flows
NLPM
(7)
Set
Vibr.
Air
bar
Pickup
Shaft
Type (4)
Spray
Rate
g/min
(5)
7MB
Gun
9MB
Gun
Prim.
N
2
Sec.
H
2
Paral/
Cross
mm
Set Air
bar
205NS G 730 33 6.6 500 75-80 -- -- 2 102-127 5.3 1.7 A 45
210NS-1 G 730 33 6.6 500 74-80 -- -- 2 102 5.3 1.7 A 83
212F-NS G 730 33 6.6 500 74-80 -- -- 2 178 5.3 1.7 A 45
303NS-1 GE 731 33 7.4 500 74-80 -- -- 2 127 5.3 0.3 A 60
350NS GE 731 44 7.4 400 75-85 Paral 4.8 1 102 5.3 0.3 A 91
404NS G 730 33 7.9
(8)
500 74-80 -- -- 1 102-152 5.3 0.3 A 113
410NS G 730 33 7.9 500 74-80 -- -- 1 76-127 5.3 0.3 A 60
430NS GE 731 66 5.7 400 75-85 -- -- 2 102 7.9 0.3 A 76
439NS GE 731 33 7.4 500 74-80 -- -- 2 152-178 5.3 0.3 A 113
439NS-2 GE 731 33 7.4 500 74-80 -- -- 1 152-178 5.3 0.3 A 113
443NS G 730 66 6.6 500 74-80 -- -- 2 127-152 5.3 0.3 A 60
445 G 730 66 6.6 500 74-80 -- -- 1 102-152 5.3 0.3 A 151
METRIC UNITS
NOTES:
hose and cable unit is 4.5 bars long.) Adjust secondary flow to attain required voltage.
clogging.
(8) Secondary gas flow can be varied 2.1 NLPM to achieve desired voltage range. DO NOT REDUCE secondary gas flow to zero,
NOR GO ABOVE 10.9 NLPM.
NLPM
(1)
Set
Amp.
(DC)
Voltage
Range
Distribu-
tion Unit
Volts
(2, 6)
Air Jet
Cooler
(1)
Powder
Port Type
(3)
Spray
Dis-
tance
mm
Carr.
Flows
NLPM
(7)
Set
Vibr.
Air
bar
Pickup
Shaft
Type (4)
Spray
Rate
g/min
(5)
7MB
Gun
9MB
Gun
Prim.
N
2
Sec.
H
2
Paral/
Cross
mm
Set Air
bar
447NS G 730 66 4.4
(8)
500 70-80 -- -- 2 102-152 5.3 0.3 A 68
450NS G 730 66 4.4 500 70-80 -- -- 2 102-178 5.3 0.3 A 68
450P G 730 66 4.4 400 65-75 -- -- 2(*) 102 5.3 0.3 A 68
451 G 730 44 6.6 500 74-80 -- -- 1 102-127 5.3 0.3 A 121
452 G 730 66 4.4 500 75-80 -- -- 2 102-178 5.3 0.3 A 68
453 G 730 66 4.4 500 70-80 -- -- 2 127 5.3 0.3 A 60
GE 731 33 4.8 500 75-85 -- -- 6 140 5.3 0.3 A 113
461NS G 730 66 6.6 500 75-80 -- -- 2 127-152 5.3 0.3 A 60
501 GE 731 66 8.3 400 75-85 -- -- 2 102-127 5.3 0.3 A 72
505 G 730 44 6.6 350 70-80 Paral 31 2 102 5.3 0.3 A 91
GE 731 44 7.4 400 70-80 Paral 31 2 114 5.3 0.3 A 91
605NS GE 731 66 2.6 350 65-75 -- -- 2 76-89 5.3 0.3 A 76
700F GE 731 44 7.4 400 85 102 31 2 102 5.3 0.3 A 53
Locations Locations
Corporate Headquarters
Switzerland
Sulzer Metco Holding AG
Zurcherstrasse 12
Building 211
CH-8401 Winterthur
SWITZERLAND
Tel: +41 52 262 30 01
Fax: +41 52 262 01 66
Americas
Brazil
Sulzer Metco Ind. e Com., Ltda
Rua So Francisco de Sales, 47
CEP 09920-450 - Diadema - SP
BRAZIL
Tel: +55 11 749 2666
Fax: +55 11 46 5124
Canada
Sulzer Canada Inc.
Sulzer Metco Division
7956 Torbram Rd. Unit # 9C
Brampton, Ontario L6T 5A2
CANADA
Tel: +1 905 458 1333
Fax: +1 905 458 1611
Mexico
Sulzer Metco (Mxico)
S.A. de C.V.
Obrero Mundial 678
Colonia Atenor Salas
Mxico, 03010 D.F.
MEXICO
Tel: +52 5 538 8725
Fax: +52 5 538 0279
United States
Sulzer Metco (US) Inc.
1101 Prospect Avenue
Westbury, NY 11590-0201
UNITED STATES OF AMERICA
Tel: +1 516 334 1300
Fax: +1 516 338 2414
Midwest Distribution
1972 Meijer Drive
Troy, MI 48084-7143
Tel: +1 248 288 1200
Fax: +1 248-288 4162
West Coast Distribution
12000 Woodruff Avenue
Downey, CA 90241-5600
Tel: +1 562 803 1060
Fax: +1 562 803 6827
Asia/Pacific
Australia
Sulzer Australia Pty. Ltd.
Sulzer Metco Division
P.O. Box 307
2/89 Gow Street
Padstow 2211 NSW
AUSTRALIA
Tel: +61 2 9796 2011
Fax: +61 2 9790 0304
Singapore
Sulzer Metco (Singapore) Pte. Ltd.
2 Loyang Lane
# 06-02
Singapore 508913
REPUBLIC OF SINGAPORE
Tel: +65 545 0870
Fax: +65 545 0816
Japan
Japan
Sulzer Metco (Japan) Ltd.
3-4-2, Hikawadai
Nerima-Ku
Tokyo, 179-0084
JAPAN
Tel: +81 3 5920 3301
Fax: +81 3 5920 3511
Europe
Belgium
Tel: +32 2 721 53 83
Fax: +32 2 725 13 16
France
Sulzer Metco
29, rue Condorcet
B.P. 87
F-38093 Villefontaine Cedex
FRANCE
Tel: +33 4 74 95 50 62
Fax: +33 4 74 94 46 98
Germany
Sulzer Metco Europe GmbH
Am Eisernen Steg 18
Postfach 1465
D-65783 Hattersheim
GERMANY
Tel: +49 6190 8090
Fax: +49 6190 3009
Sulzer Metco
Component Services GmbH
Gottfried-Linke-Strasse 205
D-38223 Salzgitter
GERMANY
Tel: +49 5341 243 0
Fax: +49 5341 243 33
Great Britain
Sulzer Metco
Westmead
Farnborough
Hants GU14 7LP
GREAT BRITAIN
Tel: +44 1252 511335
Fax: +44 1252 511230
QCoat Limited
Clarence Street
Stalybridge (Manchester)
Cheshire SK15 1QF
GREAT BRITAIN
Tel: +44 161 343 6220
Fax: +44 161 343 6221
Italy
Sulzer Metco
Via Liguria 2/29-31
I-20068 Peschiera
Borromeo (Milano)
ITALY
Tel: +39 02 5530 3186
Fax: +39 02 5530 3198
Netherlands
Sulzer Metco
Konijnenberg 37
P.O. Box 3464
NL-4800 DL Breda
NETHERLANDS
Tel: +31 76 5711 434
Fax: +31 76 5811 772
Spain
Sulzer Metco
Paseo de la Castellana, 163
E-28046 Madrid
SPAIN
Tel: +34 91 570 33 49
Fax: +34 91 570 41 72
Sweden
Sulzer Metco
Botvid Center
Fittja Backe 1
S-145 84 Stockholm
SWEDEN
Tel: +46 8 680 8200
Fax: +46 8 531 82251
Switzerland
Sulzer Metco AG (Switzerland)
Rigackerstrasse 16
CH-5610 Wohlen
SWITZERLAND
Tel: +41 56 618 81 81
Fax: +41 56 618 81 00
Visit our web site at
http://www.sulzermetco.com

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