Praxair SG-100 Operator's Manual
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Praxair SG-100 Operator's Manual

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

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Questions and answers

Andrew Hewitt
May 20, 2025

Hello, what size fasteners for the four tapped holes in the insulation ring in the middle of the gun?

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1 comments:
Mr. Anderson
May 24, 2025

The four tapped holes in the insulation ring of the Praxair SG-100 gun require 6-32 x 0.5” long stainless steel cap screws.

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Summary of Contents for Praxair SG-100

  • Page 1 To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual Manual Part Number: 05001760 Revision H Issued: 12/11...

  • Page 2: Ec Declaration Of Conformity

    EC Declaration of Conformity We, Praxair Surface Technologies, 146 Pembroke Road, Concord, NH 03301 USA, declare under sole responsibility that the Model SG-100 Plasma Spray Gun to which this declaration relates is in conformity with the relevant provisions of the...
  • Page 3 All information referred to and/or included in this manual is current as of the original issue date of this manual. Praxair Surface Technologies, Inc. makes no warranty or representation with respect to the accuracy of the information contained therein nor with respect to the suitability of the use of...
  • Page 4 To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Safety First Read This Before Using Thermal Spray Equipment WARNING Read and understand operator’s manual before using this machine. Failure to follow operating instructions could result in injury or damage to equipment.
  • Page 5 To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Generic Thermal Spray Process Sources of Information To work safely with thermal spray equipment, become familiar with these items: This manual and related documentation, especially:  Safe practices and safety guidelines described in section 1 and in...
  • Page 6 To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Conventions Throughout this manual, certain words and symbols are used to draw your attention to important information. These symbols and words have the following meaning: Praxair Surface A procedure or setting that will produce optimum results...
  • Page 7 To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ WARNING PERSONAL INJURY HAZARD Use caution when handling the powder feeder, feed lines and fittings. There is a possibility of static electricity discharge from the powder feed system which could result in significant discomfort or injury.
  • Page 8 To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Related Publications Information that can help OSHA (Occupational Safety and Health Administration) establishes mandatory federal safety regulations. For information about the regulations, refer to OSHA Standards, Code of Federal Regulations, Title 29, Part 1910.
  • Page 9 To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Oxygen, CGA Pamphlet G-4, available from the Compressed Gas Association. NFPA 50 Bulk Oxygen Systems at Consumer Sites, available from the National Fire Protection Association. NFPA 55 Compressed Gases and Cryogenic Fluids Code, available from the National Fire Protection Association.

  • Page 10: Table Of Contents

    Section 2 Equipment Description ..................21 Plasma Spray Process Description ..................21 Figure 2-1 SG-100 Specifications ..................21 Figure 2-2 SG-100 Gun Dimensions ..................22 SG-100 Gun Description ...................... 22 Water Cooling Requirements ....................22 Optional Items ........................24 A. Adapters .......................... 24 B.
  • Page 11 Receiving-Handling ......................25 SG-100 Gun Installation ....................... 25 Figure 3-1 SG-100 Installation ..................... 26 SG-100 AIR JET (Optional) ....................26 Figure 3-2 SG-100 Air Jet Installation ................. 27 SG-100 Gun Test Instructions ....................27 Section 4 Operation ......................29 Note for SG-100 Plasma Gun Users ..................30 Plasma Spray Shop Notes .....................
  • Page 12 Section 6 Parts List .......................49 SG-100 Plasma Spray gun Assembly ................... 49 Figure 6-1 SG-100 Plasma Spray Gun Assembly ..............50 SG-100 Plasma Spray Gun Assembly Parts List ..............51 SG-100 Electrode Gas Injector Configurations ..............52 Standard Hardware (non-vortex) ................52 Subsonic Optional Hardware .................

  • Page 13: Safety Guidelines

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Section 1 Safety Guidelines This section covers potential hazards and safety issues associated with thermal spraying, preparing for its use, and its finishing processes. Subjects include:  Fire prevention and protection ...

  • Page 14: General Guidelines

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ General Guidelines All persons concerned with thermal spraying must know and understand these safe practices and the safety regulations contained in established standards. Pertinent established standards are listed in "Related Publications"...

  • Page 15: Hazardous Materials

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ 1.3.3 Hazardous Materials Toxic Wastes Preparations for thermal spraying, the process itself, or subsequent finishing operations may generate toxic materials. Dispose of them according to the EPA Resource Conservation and Recovery Act (RCRA).

  • Page 16: Flow Meters

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Be sure the work area is adequately ventilated before opening any gas valves. Drain the regulator of gas and release the regulator adjusting screw before SLOWLY opening the cylinder valves. ALWAYS stand away from the direction of force when opening cylinder valves.

  • Page 17: Compressed Air

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ EXPLOSION HAZARD: NEVER USE LEAKING THERMAL SPRAY EQUIPMENT. Place a “Danger Do Not Operate” tag on the defective equipment to alert others to the unsafe condition. Obstructed gas lines caused by defective hoses, collapsed hose stems, or dirt in the gun head gas passages or nozzle jets require excessive gas pressure to obtain proper gas flow.

  • Page 18: Plasma And Arc Spray Equipment

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Properly seating and lubricating the gun's oxygen, fuel gas, and compressed air valves helps the gun operate freely and shut off completely. Extinguish gun backfires as quickly as possible.

  • Page 19: Abrasive Blast Machine

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Avoid contact between any ungrounded portion of the plasma or arc gun and the spray booth or chamber. Electrically isolate plasma guns and nozzles from support brackets to prevent stray high frequency current from damaging other electrical equipment and controls.

  • Page 20: Protecting Workers

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Protecting Workers The general requirements for the protection of thermal spraying operators and welders are the same as those published in ANSI/AWS Z49.1, Safety in Welding and Cutting; ANSI Z87.1, Standard Practices for Occupational and Educational Eye and Face Protection;...

  • Page 21: Respiratory Protection

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ 1.5.2 Respiratory Protection Respiratory protection is necessary for most spray and blast operations. Selection of device is determined, in accordance with ANSI Z88.2, by the nature, type, and magnitude of the fume and gas involved. Select only devices approved by the U.S.

  • Page 22: Noise Protection

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ When highly toxic materials are being applied, the contaminated air is considered immediately harmful and the operator MUST NOT remove the respirator. In these applications, the respirator must be equipped with an emergency auxiliary source of breathable air that the operator can breathe while working in the confined space.

  • Page 23: Noise Duration

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Table 1-2 Typical Noise Levels of Various Environments Equipment Setup Arc Guns Steel 24 V/200 32 V/500 A Powder Guns Acetylene (Normal) w/o spray booth w/spray booth w/spray booth & air jet cooling...

  • Page 24: Hearing Protection

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Table 1-3 Tolerable Noise Limits of Various Exposure Times Exposure Duration (Per Day) Sound Level (dBA) Hours Minutes 3.75 1.88 0.94 Seconds 28.12 14.06 7.03 3.52 1.76 0.88 0.44...
  • Page 25 To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ contains many variables, so each case must be treated individually. This manual can provide only general suggestions for noise control. Use engineering or administrative controls to reduce noise or noise exposure.

  • Page 26: Protective Clothing

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ outside the room. Contact Praxair Surface Technologies for additional information. Insulate Work Area Blocking the path of sound transmission by lining the work area with sound absorbing materials provides significant noise reduction. Consult noise control experts for material recommendations.

  • Page 27: Confined Spaces

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ not reflected onto the face shield. Wear aluminized gloves and dark, fire- retardant clothing. Arc spraying radiation protection is similar to that for electric arc welding and is outlined in ANSI/AWS Z49.1.
  • Page 28 To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ 1.5.5.2 Factors to Consider To eliminate the chance of gas escaping through leaks or improperly closed valves, prior to entering the confined space, close the gun valve, and shut off the gas supply at a point outside the confined space. If possible, remove the gun and hose from the confined space.
  • Page 29 To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ breathing zone. In permanent installations, the entire tool is enclosed except the front; air enters the enclosure at approximately 300 feet/minute (1.5 m/s). The hood top can be hinged to facilitate loading and unloading with a crane.

  • Page 30: Toxic Material

    Specific precautions for protecting the health of spray equipment operators vary according to the type of material being sprayed. 1.6.1 Beryllium and Lead Praxair Surface Technologies does not recommend spraying beryllium, lead, or their compounds because they are highly toxic and hazardous. 1.6.2 Cadmium Cadmium is highly toxic and hazardous.

  • Page 31: Tin And Zinc

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ 1.6.3 Cobalt, Chromium, and Tellurium The principal hazard when spraying or blasting these materials comes from ingestion, inhalation, and the subsequent absorption of fumes, dust, or vapors. The fumes and dust from chromium alloys (such as stainless steels, nickel chromium, and chromium oxide) and tellurium are toxic and hazardous.

  • Page 32: Safety Standards

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ 1.6.6 Threshold Limit Values Threshold Limit Values (TLV) are air concentration levels of hazardous materials for exposures not exceeding a total of eight hours daily. TLVs are published annually by the ACGIH.

  • Page 33: Equipment Description

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Equipment Description Section 2 2.1 Plasma Spray Process Description The plasma spray process uses plasma (hot ionized gas) to melt the powder and propel it onto the substrate through the expanding plasma gas.

  • Page 34: Sg-100 Gun Description

    Mini-Gun II or a Model 2700 Mini-Gun III with a 12 or 24-inch extension. Both can be used as internal diameter sprayers. The SG-100 gun operates at a maximum power level of 100 KW and has interchangeable, water-cooled, self-aligning electrodes for multi-mode operation.
  • Page 35 To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Figure 2-3 Conditions: Standard Hoses, Cables and Hi Frequency Arc Starter. A. Model 3202 Pump B. Heat Exchanger Issued: 12/11 Page 23...

  • Page 36: Optional Items

    F. Manipulator Adapters (Gun Mounts) There are adapter options available for easier mounting of the SG-100 gun to a robot (P/N 601214 for an ABB 2400, P/N 601553 for a Fanuc M20IA), a Fanuc robot and 6600 manipulator (P/N 5003938).

  • Page 37: Installation

    3.2 SG-100 Gun Installation The SG-100 gun must be installed onto a secure structure such as a robot arm, X-Y manipulator, or lathe, using one of the available optional brackets.

  • Page 38: Sg-100 Air Jet (Optional)

    5. Connect Powder In hose to 3/8" fitting on curved powder tube. Tighten securely. 3.3 SG-100 AIR JET (Optional) The SG-100 Air Jet (Part No. 05004566) cools the part being coated. The Air Jet is optional. Issued: 12/11 Page 26...

  • Page 39: Sg-100 Gun Test Instructions

    See Figure 3-2 and install Air Jet as follows: 1. Connect supply hose to house air supply. 2. Connect clamps to front of the gun. Tighten clamps with screw- driver. Figure 3-2. Model SG-100 Air Jet Clamp Supply Hose Clamp 3.4 SG-100 Gun Test Instructions...
  • Page 40 To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Wear hearing protection. Operation of a plasma gun generates strong noise emissions (> 130 dBa), which can cause damage or loss of hearing. 3.4.1 Setup and pretest: 3.4.1.1 Mount the gun.

  • Page 41: Operation

    ELECTRICALLY ISOLATE SG-100 gun when gun is to be machine mounted. Only use non-conductive brackets supplied by the manufacturer for machine mounting of SG-100 gun.

  • Page 42: Note For Sg-100 Plasma Gun Users

    See Section 6-2 for alternative configurations for the SG- 100 gun. The SG-100 comes with one powder tube assembly (P/N 5004378). The powder tube can be installed on either side of the gun or a second powder tube can be used for dual radial injection. Should only one powder tube be needed, a powder tube plug (P/N 1083A-107A) and o-ring (P/N #02- 006S) is placed where the other tube would go.

  • Page 43: Plasma Spray Shop Notes

    This is because of the variations in their physical and thermal properties. The relative gas velocity for Praxair Surface Technologies’ (PST) plasma guns is given in terms of subsonic, MACH I, and MACH II. Gas velocity dictates powder particle velocity.

  • Page 44: Surface Preparation

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Powder that is too widely distributed (too many particles above and below the specified range) reduces deposit efficiency, produces poor quality coatings, and negatively affects gun operation. PST considered these factors when setting up specifications for use of this equipment with PST Powders.

  • Page 45: C-3. Masking

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Make sure the air supplied to the grit blast equipment is clean, oil- free, and dry. C-3. Masking Sometimes the plasma sprayed coating must be confined to a specific area of the substrate.

  • Page 46: Proper Operating Parameters

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Some circumstances may call for adding small percentages of either helium or other secondary gases to the arc gas. If the plasma is not hot enough to completely melt the powder, a small percentage of secondary gas is added to the primary arc gas.

  • Page 47: Powder Injection

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ F. Powder Injection An important aspect of the plasma spray operation is obtaining maximum heat transfer efficiency from the plasma to the powder particles. There is a pronounced temperature gradient along the length and across the width of the plasma, so powder particles should be entrained in the core of the plasma, not in the cooler outer regions.

  • Page 48: G-4. Shaft Coupling

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ G-4. Shaft Coupling In some instances, certain combinations of powder characteristics and wheel speed can cause harmonic oscillations of 1264 old style electric motor shaft coupling (P/N 015117), producing pulsation.

  • Page 49: G-7. Powder Tube O-Ring

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ G-7. Powder Tube O-ring When worn or damaged, the o-ring in the anode powder port can upset the powder stream and cause pulsing. Pulsing may also result if the o-ring is left out during gun assembly.

  • Page 50: Traverse Speed/Pitch

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ One time constant interaction relates to gun motion. For example, assume the gun’s linear motion is one second left to right. Assume also, that powder traverses the hose’s moving portion in one second.

  • Page 51: Sg-100 Plasma Gun Spray Parameters

    Model SG-100 Plasma Spray Gun Operator’s Manual 4.2 SG-100 Plasma Gun Spray Parameters Sulzer Metco Primary Primary Secondary Secondary Material Material Composition Size Anode Cathode Injector Current Gun V Gas Flow Gas Flow Carrier Powder Feed Standoff µm scfh scfh...
  • Page 52 To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual Notes Issued:12/10 Page 40...

  • Page 53: Maintenance

    4.3.2. 5.2 Anode Removal and Maintenance The anode is one of the SG-100 gun’s most critical parts. Anode life is affected by unit operating conditions and regular maintenance. Remove, clean, and inspect the anode after each use, and replace as necessary until a regular maintenance and replacement schedule for the spray parameters used becomes apparent.

  • Page 54: Figure 5-1 Anode Removal Tool Insertion

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ 2. Remove three socket head cap screws (item 13) from front cover plate (item 1). Remove cover plate from gun body. 3. Insert anode removal tool into front housing slot (Fig. 5-1).

  • Page 55: Figure 5-3 Sg-100 Gun, Exploded View

    Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Figure 5-3. SG-100 Gun, exploded view Inspect anode O-ring for cuts or nicks that may prevent the anode from sealing properly against the powder tube. Do not use lubricant on anode O-ring.

  • Page 56: Figure 5-4 Sg-100 Gun, Assembled View

    9. Push anode into place. When properly seated, the face of the anode will seat flush with the front housing. Figure 5-4. SG-100 Gun, assembled view 10. Reinstall front cover plate (item 1) and secure onto gun with three socket head cap screws (item 13) removed in Step 2.

  • Page 57: Cathode Removal & Maintenance

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ 5.3 Cathode Removal & Maintenance Figure 5-5. Cathode Removal Tool ELECTRIC SHOCK can kill; Do not touch live electrical parts. Disconnect power source from input power before inspecting or servicing gun.

  • Page 58: Complete Sg-100 Disassembly & Maintenance

    Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ 5.4 Complete SG-100 Disassembly & Maintenance ELECTRIC SHOCK can kill. Do not touch live electrical parts. The gun is electrically “live” while power source is ON (approx. 32 VDC). Disconnect input power before inspecting or servicing gun.

  • Page 59: Complete Sg-100 Gun Reassembly

    Check O-rings for signs of over heating, damage, or wear spots. Replace if required. 5.5 Complete SG-100 Gun Reassembly See Figures 5-3 and 5-4, and reassemble SG-100 gun as follows: 1. Install gas injector (item 8) into insulator housing (item 3) with taper toward rear of the insulator housing.
  • Page 60 To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ 5. Install rear insulator housing (item 4) onto insulator housing (item 3). Be sure O-ring (item 16) fits properly in detent of insulator housing. 6. Install four socket head cap screws (item 14) into holes in front housing (item 2).

  • Page 61: Parts List

    Inspect labels on this unit every six months for legibility. Maintain all precautionary labels in a clearly readable state and replace when necessary. See parts list for label part numbers. 6.1 SG-100 Plasma Spray Gun Assembly Item Part Number Description...

  • Page 62: Figure 6-1 Sg-100 Plasma Spray Gun Assembly

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Figure 6-1 SG-100 Plasma Spray Gun Assembly, Rev. M Issued: 12/11 Page 50...

  • Page 63: Sg-100 Plasma Spray Gun Assembly Parts List

    Notes: See Section 6-2 for alternative configurations for the SG-100 gun. The SG-100 comes with one powder tube (item 9) assembled. The powder tube can be installed on either side of the gun. Should only one powder tube be needed, a powder tube plug (item 11) and o-ring (P/N #02-006S, installed but not shown) is placed where the other tube would go.

  • Page 64: Sg-100 Electrode Gas Injector Configurations

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ 6.2 SG-100 Electrode - Gas Injector Configurations Standard Hardware (non-vortex) 02083-120 cathode 02083-730 anode 03083-112 gas injector Optional Subsonic Hardware 03083-145 anode 02083-120 cathode 03083-175 anode 03083-113 gas injector...

  • Page 65: Mach I Optional Hardware

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Mach I Optional Hardware 02083-355 anode 01083A-112 cathode 02083-358 anode 03083-113 gas injector 02083-155 anode Mach II Optional Hardware 01083-104 cathode 02083-100 anode 03083-110 gas injector Issued: 12/11...

  • Page 66: Optional Items

    (P/N 5004566) consists of a hose assembly and two adjustable nozzles that clamp to the front of the gun. F. Manipulator Adapters (Gun Mounts) There are adapter options available for easier mounting of the SG-100 gun to a robot (P/N 800825) and manipulator (P/N 5003938). Issued: 12/11...

  • Page 67: Sg-100 Hoses And Cables

    To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ 6.4 SG-100 Gun Hoses & Cables STANDARD LENGTH DESCRIPTION 0985-2-L HOSE, GAS TO PLASMA GUN 601215-L HOSE, POWDER, POWDER FEEDER TO PLASMA GUN 0987-7-L CABLE, POWER, WATER COOLED, DC NEGATIVE (-), TO PLASMA GUN...
  • Page 68 To Table of Contents Model SG-100 Plasma Spray Gun Operator’s Manual _____________________________________________________________________________________________________________________ Notes Issued: 12/11 Page 56...

  • Page 69: Praxair Surface Technologies, Inc

    To Table of Contents Praxair Surface Technologies, Inc. 146 Pembroke Road Concord, NH 03301 www.praxairsurfacetechnologies.com psti-info@praxair.com Telephone: 1-603-224-9585 Fax: 1-603-225-4342...

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