Model BP400 Arc Spray System Rev H

Model BP400
Arc Spray System

Operators Manual
Manual Part Number: 05001756
Rvision H
Issued: 08/13
EC Declaration of Conformity
We, Praxair Surface Technologies, 146 Pembroke Road, Concord, NH 03301 USA, declare under
sole responsibility that the Model PF400R Control Console with BP400 Arc Spray Gun to which
this declaration relates is in conformity with the relevant provisions of the
following standard(s) or other document(s):
Electromagnetic Compatibility Directive: 2004/108/EC
EN 60974-10:2003/IEC 60974-10 Edition 2:2007
CISPR 11:2003 Conducted Emissions
CISPR 11:2003 Radiated Emissions
IEC 61000-3-11:2000 Flicker
IEC 61000-3-12:2004 Harmonics
IEC 61000-4-2: Ed. 2.0; 2008-12 Electrostatic Discharge
IEC 61000-4-3: Ed. 3.1; 2008-04 Radiated Immunity
IEC 61000-4-4: Ed. 2.0; 2004-07 EFT Burst
IEC 61000-4-5; Ed. 2.0; 2005-11 Surge Immunity
IEC 61000-4-6; Ed. 3.0; 2008-10 Conducted RF Immunity
IEC 61000-4-11: Ed. 2.0; 2004-03 Voltage Dips and Interrupts
Machinery Directives 2006/42/EC, Low Voltage Directive(s) 2006/95/EC
EN60204-1:2006
Equipment: Arc Spray System
Brand Name: Praxair Surface Technologies and TAFA Inc.
Model: BP400 Spray System with BP400 Arc Spray Gun
We hereby declare that the equipment specified above conforms to the above directive(s) and
standard(s).
Signature:
Full Name:
Position:
Stephen Ford
Engineering Manager
Praxair Surface Technologies, Inc.
146 Pembroke Road
Concord, NH 03301
(603) 224-9585 phone
(603) 225-4342 fax
DISCLAIMERS
All information referred to and/or included in this manual is current as of the original issue date of this manual.
Praxair Surface Technologies, Inc. makes no warranty or representation with respect to the accuracy of the
information contained therein nor with respect to the suitability of the use of such information outside Praxair
Surface Technologies, neither does Praxair Surface Technologies assume responsibility for any injury or
damage which may result, directly or indirectly, from the use of such information.
The information contained herein is offered for use by technically qualified personnel at their discretion and risk
without warranty of any kind. Praxair Surface Technologies is constantly improving its products, and
specifications are subject to change without notice.
This manual could include technical inaccuracies or typographical errors. Changes are made periodically to the
information herein; these changes will be incorporated in subsequent revisions of the manual. Praxair Surface
Technologies reserves the right to make improvements and/or changes to the product(s) and/or programs
described in this manual at any time and without notice. Illustrations are meant to be representative of, but not
exact duplicates of, existing equipment.
BUSINESS CONFIDENTIAL
THIS MANUAL CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF PRAXAIR
SURFACE TECHNOLOGIES. THIS INFORMATION IS PROVIDED IN CONFIDENCE SOLELY
FOR USE WITH OUR MODEL BP400 ARC SPRAY SYSTEM. THIS MANUAL MAY NOT BE
REPRODUCED IN ANY FORM OR ITS CONTENTS DISCLOSED TO THIRD PARTIES WITHOUT
THE PRIOR WRITTEN CONSENT OF PRAXAIR SURFACE TECHNOLOGIES.
TRADEMARK INFORMATION
Praxair and the Flowing Airstream design are trademarks or registered trademarks of Praxair Technology, Inc.
in the United States and other countries and CoArc, TAFA , and TAFA with Flame design, and the Flame
design are trademarks or registered trademarks of Praxair S.T. Technology, Inc. in the United States and other
countries.
Other trademarks used herein are trademarks or registered trademarks of their respective owners.

Printed in the United States of America. Copyright 2013 Praxair S.T. Technology, Inc.
Model BP400 Arc Spray System

Operators Manual
_____________________________________________________________________________________________________________________
Safety First
Read This Before Using

Thermal Spray Equipment
WARNING
Read and understand operators manual before using this machine. Failure
to follow operating instructions could result in injury or damage to
equipment.
Thermal spraying is powerful technology. Do not use equipment

carelessly or without observing safe practices. Be safe!
Learn the recommended procedures and standards.
Failure to follow recommended procedures and standards
can result in severe injury to people and damage to equipment.
Who should use Thermal Spray Equipment?

Use the equipment only if you have been trained fully in safely using it.
Do not allow untrained persons to install, operate, or maintain the
equipment.
Understand what to do before you do it!

Make sure that you have read and understand the contents of this manual especially the safety guidelines and operating procedures - before
installing, operating, or maintaining this equipment. Contact a Factory
Representative if you do not fully understand any guidelines or
instructions.
Issued: 8/13
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Generic Thermal Spray Process
Sources of Information
To work safely with thermal spray equipment, become familiar with these
items:
This manual and related documentation, especially:

- Safe practices and safety guidelines described in section 1 and in
highlighted paragraphs throughout this guide
- Operating instructions (see section 4)
Technical bulletins included with or referred to in this manual. This

includes industry publications that contain standards that may apply to
your work. (See page vi of this guide for a list of industry
publications.)
Labels, tags, other instructions, and warnings that come with or are
attached to the equipment
Guidelines and practices your specific site has established as standard
About This Manual
This manual presents information about setting up, operating, maintaining,

and troubleshooting your equipment.
Issued: 8/13
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Conventions
Throughout this manual, certain words and symbols are used to draw your
attention to important information. These symbols and words have the
following meaning:
Praxair Surface
Technologies
RECOMMENDS
A procedure or setting that will produce optimum results
Information that can help to operate the equipment more effectively.
Refer to the manual before doing any maintenance.
Wear respirator.
Risk of eye injury. Eye protection required.

Wear opaque eye protection.
Wear protective clothing, gloves.
Wear hearing protection.
Pressure Relief
Issued: 8/13
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HAZARD
Hazards that can result in minor or major damage to equipment,
bodily injury to people, and how to prevent such hazards.
EXPLOSION HAZARD
ELECTRIC SHOCK HAZARD
FIRE HAZARD
HIGH TEMPERATURE HAZARD
ELECTROMAGNETIC FIELDS HAZARD
LIGHT EMISSION HAZARD
People with Heart Pacemakers Not Allowed
Issued: 8/13
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Related Publications
Information that can help
OSHA (Occupational Safety and Health Administration) establishes

mandatory federal safety regulations. For information about the
regulations, refer to OSHA Standards, Code of Federal Regulations,
Title 29, Part 1910.
Handling compressed gas is among the safety hazards associated with
thermal spraying. ANSI/AWS Z49.1, Safety in Welding and Cutting
and the Williams-Steiger Occupational Safety and Health Act of 1970
(84 Stat. 1943) cover safe handling of compressed gases. More recently,
the Resource Conservation and Recovery Act (RCRA), dealing with the
disposal of toxic wastes, potentially affects the thermal spray industry.
Occupational Safety and Health Act Standards (29CFR 1910),
available from the Superintendent of Documents, U.S. Government
Printing Office.
Ventilation, Occupational Safety and Health Standard OSHA
1910.94, available from the Occupational Safety and Health
Administration.
Safety in Welding and Cutting, AWS/ANSI Z49.1, available from the
American Welding Society.
Environmental, Health, and Safety Guidelines, available from TSS an
affiliate society of ASM International (ASM TSS).
Requirements for Personal Eye and Face Protection, ANSI Z87.12003, available from the American National Standards Institute.
Standard Practices for Respiratory Protection, ANSI Z88.2, available
from the American National Standards Institute.
Safety Requirements for Industrial Head Protection, ANSI Z89.1,
available from the American National Standards Institute.
National Electrical Code, NFPA 70-2011, available from the National
Fire Protection Association, updated annually.
Safe Handling of Compressed Gases, CGA Pamphlet P-1, available
from the Compressed Gas Association.
Issued: 8/13
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Oxygen, CGA Pamphlet G-4, available from the Compressed Gas

Association.
NFPA 50 Bulk Oxygen Systems at Consumer Sites, available from the
National Fire Protection Association.
NFPA 55 Compressed Gases and Cryogenic Fluids Code, available
from the National Fire Protection Association.
NFPA 30 Flammable and Combustible Liquids Code, available from
the National Fire Protection Association.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
ANSI/AWS F3.2, available from the American Welding Society.
Safety Release Device Standards - Cylinders for Compressed Gases,
CGA Pamphlet S1.1-1963 and 1965 and S1.2-1963, available from the
Compressed Gas Association.
Power and Process Piping Package, ANSI B31.1, available from the
American National Standards Institute.
Acetylene, CGA Pamphlet G-1, available from the Compressed Gas
Association.
NFPA 51Standard for the Design and Installation of Oxygen-Fuel Gas
Systems for Welding, Cutting, and Allied Processes, available from the
NFPA 51B Standard for Fire Prevention During Welding, Cutting
and Other Hot Work, available from the National Fire Protection
Association.
ANSI/NFPA 58 Liquefied Petroleum Gas Code, available from the
Industrial Ventilation: A Manual of Recommended Practice ACGIH
(25th Ed., 2004)
American National Standard for Hand Protection Selection Criteria,
105-2011, available from the International Safety Equipment Association
Issued: 8/13
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Table of Contents
Read This Before Using Thermal Spray Equipment ................................................................ iii
Section 1
Safety Guidelines....................................................................................................1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Section 2
Equipment Description ........................................................................................21

2.1
2.2
2.3
2.4
2.5
Issued: 8/13
Reminder: Safety First! .......................................................................................................... 1

General Guidelines ................................................................................................................. 2
Fire Protection and Prevention .............................................................................................. 2
1.3.1
Keep Work Areas Clean .......................................................................................... 2
1.3.2
High Temperatures ................................................................................................... 2
1.3.3
Hazardous Materials ................................................................................................ 3
Safe Operating Conditions ..................................................................................................... 3
1.4.1
Compressed Gas Cylinders ...................................................................................... 3
1.4.2
Flow Meters ............................................................................................................. 4
1.4.3
Compressed Air ....................................................................................................... 5
1.4.4
Flame Spray and HVOF Equipment ........................................................................ 5
1.4.5
Plasma and Arc Spray Equipment ............................................................................ 6
1.4.6
Abrasive Blast Machine ........................................................................................... 7
1.4.7
Handling and Manipulating Equipment ................................................................... 7
Protecting Workers ................................................................................................................. 8
1.5.1
Eye Protection .......................................................................................................... 8
1.5.2
Respiratory Protection.............................................................................................. 9
1.5.3
Noise Protection ..................................................................................................... 10
1.5.3.1
Noise and Noise Level ......................................................................... 10
1.5.3.2
Noise Duration ..................................................................................... 11
1.5.3.3
Hearing Protection ............................................................................... 12
1.5.4
Protective Clothing ................................................................................................ 14
1.5.5
Confined Spaces..................................................................................................... 15
1.5.5.1
Rapid Emergency Exit ......................................................................... 15
1.5.5.2
Factors to Consider .............................................................................. 15
Toxic Material ...................................................................................................................... 18
1.6.1
Beryllium and Lead ................................................................................................ 18
1.6.2
Cadmium ................................................................................................................ 18
1.6.3
Cobalt, Chromium, and Tellurium ......................................................................... 18
1.6.4
Tin and Zinc ........................................................................................................... 19
1.6.5
Solvents .................................................................................................................. 19
1.6.6
Threshold Limit Values ......................................................................................... 19
Safety Standards ................................................................................................................... 20
System Components ............................................................................................................. 21

System Overview ................................................................................................................. 22
Component Features ............................................................................................................. 23
2.3.1 BP400 Gun Features ................................................................................................... 23
2.3.2 Power Source Features ............................................................................................... 24
2.3.3 PF400R Wire Control Console Features .................................................................... 25
Specifications ....................................................................................................................... 25
BP400 System Options ......................................................................................................... 26
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Section 3
Installation ...................................................................................................27
3.1 Location.......................................................................................................................... 27
3.2 Receiving and Handling ................................................................................................. 27
3.3 Installation: Power Source, Gun, and Wire Control Console ......................................... 28
3.3.1 Connect Compressed Air Source to PF400R ...................................................... 29
3.3.2 Connect PF400R Console to BP400 ................................................................... 29
3.3.3 Connect TCV 400 Power Source to Wire Control Console ................................ 31
Section 4
Operation .....................................................................................................35
4.1 Operating Parameters ..................................................................................................... 35
4.2 Surface Preparation ........................................................................................................ 35
4.2.1 De-greasing and Cleaning ................................................................................... 35
4.2.2 Roughening Methods .......................................................................................... 36
4.2.3 Factors to Consider.............................................................................................. 37
4.2.4 Masking ............................................................................................................... 38
4.3 Part Cooling.................................................................................................................... 39
4.4 Gun Manipulation........................................................................................................... 39
4.4.1 Atomizing End Point ........................................................................................... 40
4.5 Control Console ............................................................................................................ 41
4.5.1 Miniature Air Regulator ...................................................................................... 42
4.5.2 BP400 Gun Power Trigger .................................................................................. 42
4.6 Installing and Threading the Wire Spool ...................................................................... 43
4.7 System Check-out ......................................................................................................... 46
4.8 System Shutdown .......................................................................................................... 47
4.9 Spray Settings ................................................................................................................ 47
Section 5
Maintenance & Troubleshooting ...............................................................49

5.1 Maintenance ................................................................................................................... 49
5.1.1 BP400 Gun Parts ................................................................................................. 50
5.1.2 Coaxial Cables and Liner .................................................................................... 51
5.1.3 Air Filter .............................................................................................................. 52
5.1.4 Speed Control Unit .............................................................................................. 53
5.1.5 Timer ................................................................................................................... 53
5.2 Troubleshooting ............................................................................................................. 53
Figure 5-2 BP400 System Electrical Schematic ................................................................... 56
Section 6
Parts List ......................................................................................................57

Figure 6-1
Figure 6-2
Figure 6-3
Figure 6-4
Figure 6-5
Figure 6-6
Figure 6-7
Figure 6-8
Figure 6-9
Figure 6-10
Figure 6-11
Figure 6-12
Figure 6-13
Figure 6-14
Issued: 8/13
BP400 Electric Arc Thermal Spray System .................................................... 57

PF400R Wire Feeder Assembly ...................................................................... 58
PF400R Wire Feeder Assembly ...................................................................... 59
PF400R Wire Feeder Control Console ........................................................... 60
Spool Support ................................................................................................. 65
Drive Roll Assembly....................................................................................... 66
BP400 Electric Arc Thermal Spray Gun ......................................................... 68
BP400 High Velocity Conversion Kit, 14 GA (2.3 mm) ................................ 70
BP400 Fan Spray Conversion Kit, 14 GA (2.3 mm) ...................................... 72
BP400 Fan Spray Conversion Kit, 11 GA (1.6 mm) ...................................... 74
BP400 / PF400R Conversion Kit to 11 GA (1.6 mm) .................................... 76
Coaxial Cable Parts ......................................................................................... 78
12 Angled Extension - OPTIONAL .............................................................. 80
24 Angled Extension - OPTIONAL .............................................................. 82
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Figure 6-15 12 Straight Extension - OPTIONAL ............................................................. 84

Figure 6-16 24 Straight Extension - OPTIONAL ............................................................. 86
Table 6-18 Tips for BP 400 and Extension Gun................................................................... 88
Table 6-19 Air Caps and Nozzles for BP 400 and Extension Gun ....................................... 88
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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:
1.1
Fire prevention and protection

Safe operating conditions
Flame spray and HVOF equipment
Plasma and arc equipment
Abrasive blast machines
Safe operation of the equipment
Workers protection
Ventilation
Toxic material handling
Relevant safety standards
Reminder: Safety First!

Thermal spraying equipment is very powerful. Do not use equipment
carelessly or without observing safe practices. Be safe! Learn the
recommended procedures and standards.
Failure to follow
recommended procedures and standards can result in severe damage to
equipment and injury to people.
Use the equipment only if you have been trained fully in its safe
operation. Do not allow untrained persons to install, operate, maintain,
or troubleshoot the equipment.
Make sure that you have read and understand the contents of this
manual - especially the safety guidelines and operating procedures before installing, operating, or maintaining this equipment. Contact a
Factory Representative if you do not fully understand any guidelines or
instructions.
Issued: 10/11
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1.2
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" on page vii.
Information presented in this manual and on various labels, tags, and
plates on the unit pertains to equipment design, installation, operation,
maintenance, and troubleshooting that should be read, understood, and
followed for the safe and effective use of this equipment.
The installation, operation, maintenance, and troubleshooting of thermal
spray equipment requires practices and procedures that ensure personal
safety and the safety of others. Therefore, this equipment is to be
installed, operated, and maintained by qualified persons as specified in this
manual and in accordance with all applicable codes such as, but not
limited to, those listed in section 1, and the corresponding sections of the
manual. You should thoroughly understand and comply with local, state,
and federal (OSHA) health standards, especially when handling toxic
materials.
1.3
1.3.1
Fire Protection and Prevention

Work Areas
Keep the work area clean! Avoid accumulating metal dusts. Inspect
rafters, tops of booths, and floor cracks for dust accumulation.
NEVER store paper, wood, oily rags, or cleaning solvents within the
spray room or enclosure.
1.3.2
High Temperatures
Thermal spraying operations generate extremely high temperatures.
NEVER point thermal spray equipment at any person or flammable
material.
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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).
Flammable Solvents and Sealer Bases
Certain de-greasing solvents and sealer bases are flammable and require
special use, handling, and storage precautions in and around the thermal
spray area.
Metal Dusts and Powders
Treat airborne metal dusts, finely divided solids, or accumulations as
explosives. Minimize the danger from dust explosions by providing
adequate ventilation in spray booths. Install a cartridge-type dry dust
collection system to collect spray dust.
1.4
1.4.1
Safe Operating Conditions

Compressed Gas Cylinders
Always comply with local, state, municipal, and federal regulations
regarding compressed gas cylinder storage and follow recommendations
in ANSI/AWS Z49.1, Safety in Welding and Cutting; CGA Pamphlet
P-1, Safe Handling of Compressed Gases; NFPA 55, Compressed &
Liquefied Gases in Portable Cylinders; NFPA 51, Oxygen-Fuel Gas
Systems in Welding and Cutting; and NFPA 51B Standard for Fire
Prevention in the Use of Cutting & Welding Processes. Improper
storage, handling, and use of gas cylinders Creates A Safety Hazard. If
the site plan includes manifolding cylinders to permit longer spray times
before changeover, follow ANSI/AWS Z49.1 recommendations in
designing the plan.
NEVER use oil or grease on oxygen equipment. Use ONLY special
oxidation- resistant lubricants. Consult the equipment manufacturers or a
qualified dealer for more information.
Issued: 10/11
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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.
Install pressure reducing regulators in accordance with ANSI/AWS Z49.1.
Use only the appropriate regulator for each gas cylinder: USE ONLY
ACETYLENE REGULATORS ON ACETYLENE TANKS OR
MANIFOLD SYSTEMS. Always use the correct size wrench to connect
the regulator to the cylinder valve outlet; NEVER force or overtighten a
connection.
NEVER use oil or grease on a regulator.
1.4.2
Flow Meters
Install and use flow meters in accordance with ANSI/AWS Z49.1. Avoid
unsafe operating conditions and ensure proper flame balance by installing
backflow prevention devices in conjunction with the flow meters. Place a
protective shield on flow meters with glass tubes.
Install and use hose and hose connections according to ANSI/AWS Z49.1
and the Specification for Rubber Welding Hose published by the
Rubber Manufacturers Association and the CGA. Handle hoses carefully
to avoid damage. Use hoses only in the applications for which they are
designed. Blow out hoses to remove any dust. Avoid any ignition sources.
Turn regulator adjusting screws slowly to prevent surges that may crack or
burst flow meter tubes. Overtightening can collapse the nipple nose, so
NEVER OVERTIGHTEN the connecting nuts on pressure reducing
regulators and flow meters. If a fitting does not seal without undue force,
replace it.
NEVER use a flame to check for gas leaks. Use soapy water to check all
hose connections for leaks. Soapy water provides a safer, more sensitive
test.
If any connections leak, depressurize, open the connection, clean the
sealing surfaces and threads, re-assemble, pressurize, and test for leaks. If
a leak persists, depressurize the system.
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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.
If required oxygen and fuel gas pressure are more than 3 psi (0.2 bar) over
the recommended pressure, check for a fouled nozzle or incorrect air cap.
Low pressures often indicate a serious leak. Shut down the equipment and
correct the condition before restarting the system.
EXPLOSION HAZARD:
Acetylene pressures exceeding 15 psi (1.03 bar) may cause the gas to
detonate. If this pressure of 15 psi (1.03 bar) is insufficient, use another
fuel gas.
1.4.3
Compressed Air
Always refer to gases by their proper names to avoid confusion.
Never use compressed air, oxygen, or fuel gas to clean clothing.
For thermal spraying or blasting operations, use compressed air only at
recommended pressures. Keep the air line free of oil and moisture.
Consult an equipment dealer for filter and after-cooler recommendations.
1.4.4
Flame Spray and HVOF Equipment

Thoroughly read and understand this manual and familiarize all operators
with gun operation before lighting the gun. Maintain guns according to
recommendations.
PERSONAL INJURY (BURN) HAZARD:
Using a match to light a flame spraying gun can result in serious injury.
Use a friction lighter, pilot light, or arc ignition instead.
Issued: 10/11
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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.
Determine the cause of gun backfires or blowouts BEFORE relighting.
When you have completed spray operations, when you are shutting down
the equipment, or when you leave the equipment unattended, release all
gas pressure from the regulators and hoses.
EXPLOSION OR FIRE HAZARD:
NEVER hang a flame spraying gun or its hoses on regulators or cylinder
valves.
1.4.5
Plasma and Arc Spray Equipment

Plasma and arc spray equipment differ from flame and HVOF equipment.
They use high voltages and amperages that represent an electrical hazard.
Train operators how to use the equipment safely before they actually use
it. Specifically, ensure that operators know and understand all the
operating and safety recommendations in the operator manuals. Always
observe standard safety precautions for electrical equipment and operate in
accordance with ANSI/AWS Z49.1.
Frequently clean arc guns and power supplies to prevent metal dust
accumulation that causes electrical short circuits. Properly insulate or
ground the wire feed units used with the arc spray equipment. If the gun is
suspended, insulate or ground the suspension hook. Ground or insulate all
exposed plasma gun electrodes and cable connections. Interconnect all
ground cables.
Periodically inspect cables, insulation, hoses, and gas lines. All
pushbuttons, pilot lights, plugs, and cables should be intact and meet
ANSI/NFPA 70-2011, National Electrical Code standards. Repair or
replace faulty equipment at once. Never adjust, clean, or repair any part of
the power supply, console, or gun without first disengaging the entire
system, including the power supply.
Issued: 10/11
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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.
1.4.6
Abrasive Blast Machine

Maintain and inspect abrasive blast machines according to manufacturer's
instructions. Remove and repair or replace worn parts as needed. Do not
exceed recommended air pressure in the blast tank.
Keep blast hoses as straight as possible between the blast machine and
blasting area. Sharp hose bends cause excessive friction and wear that can
lead to a blowout at those points. If hoses must be curved around an
object, use long radius curves. Store blast hoses in cool, dry areas.
Be sure blast hose controls function properly. They should require
continuous pressure on the activating lever for operation. Releasing the
lever should cause the system to shut off (dead man control).
PERSONAL INJURY:
NEVER point a blast nozzle at a person.
Most blasting operations require respiratory protection for the operator.
Select, operate, and maintain the protective device according to ANSI
Z88.2, Standard Practices for Respiratory Protection, described in
section 1.5.2.
1.4.7
Handling and Manipulating Equipment

Most thermal spray and blasting applications require rotation or other
manipulation of the part being worked on. Some handling equipment can
impart high rotational speeds to parts being coated. Affix and balance
parts when necessary. Provide protection for the operator in case a
rotating part becomes airborne. Never leave operating equipment
unattended.
Issued: 10/11
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1.5
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; ANSI Z88.2,
Standard Practices for Respiratory Protection; and ANSI Z89.1,
Standard Practices for Industrial Head Protection with Low Voltage
Hazards.
1.5.1
Eye Protection
Spraying and blasting operations require eye protection in the form of
helmets, hand shields, face shields, or goggles. See ANSI Z87.1 and
Z89.2 for recommendations. Operators MUST use protection against
infrared and ultraviolet radiation and flying particles. Provide all helpers
and adjacent operators with suitable eye protection as well. Equip the eye
protection with a suitable filter plate to protect against ultraviolet, infrared,
and intense visible light radiation (see Table 1-1).
Table 1-1
Eye Protection
Operation
Wire Flame Spraying (except Molybdenum)

Molybdenum Wire Spraying
Flame Spraying of Metal Powder
Flame Spraying of Exothermic Ceramic Powder or Rod
Plasma and Arc Spraying
Arc Bonding
Fusing Operations
Required Type of
Eye Protection
Shades 2-4
Shades 3-6
Shades 3-6
Shades 4-8
Shades 9-12
Shades 5-6
Shades 4-6
In thermal spray operations where additional respiratory protection is not

required, operators may wear eye protecting goggles alone. The goggles
should have indirect ventilating fins to reduce fogging and eliminate
danger from flying particles. In plasma spray operations, replace the
goggles with helmets or hand shields that provide face, chin, and neck
protection from infrared and ultraviolet radiation.
When blasting, use face shields or helmets equipped with dust hoods to
protect eyes, face, chin, and neck. Provide respiratory protection, as well
as other protection discussed in the following paragraphs.
Issued: 10/11
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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. Bureau of Mines, National Institute of
Occupational Safety and Health (NIOSH), or an other approved
authority. Suggested devices for typical thermal spraying and blasting
operations include:
Blasting in the open: use a mechanical filter respirator with a face
shield and dust hood or a self-contained breathing apparatus.
Thermal spraying in confined or semi-confined spaces: use an air line
respirator. Use a device similar to the one described below for abrasive
blasting.
Abrasive blasting in confined or enclosed spaces: use a continuous
flow air line respirator consisting of a continuous flow air line respirator,
a full face piece or helmet, and dust hood sufficient to protect the head and
neck from rebounding abrasive material. Minimum air flow to the
respirator should be 4 CFM (113.3 L/minute) at the face piece and 6 CFM
(170 L/minute) entering the helmet or hood. Fresh air blowers are
preferred to compressed air as an air source of respirator air. If adequate
ventilation is not provided, use an in-line vortex cooler when possible for
operator comfort. Filter the air supply line to remove objectionable odors,
oil or water mist (or both), and rust particles from the air. Locate the air
intake to ensure the respirator receives clean, dry air (CDA). If gaseous
air contaminants such as carbon monoxide are possible, use a separate air
purifier. Grade D or better compressed air is considered breathable.
Thermal spraying in an open or a well-ventilated work area: additional
respiratory protection may not be necessary. In borderline cases, use
approved mechanical filter respirators for protection against dust and
metal fumes. Borderline cases are those that consist of light work or short
duration with nontoxic materials, but with some dust exposure.
Continuous flow air line respirators are adequate for thermal spraying
operations involving most commonly used materials. If the respirator air
supply fails and the contaminant in the space is not immediately harmful
to health, the operator may stop operations, remove the supply line, and
return to breathable air.
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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.
1.5.3
Noise Protection
The Occupational Safety and Health Administration (OSHA) requires
employers to provide safe working conditions. OSHA also requires
employees to comply with all rules, regulations and orders that apply to
their actions and conduct. OSHA does not provide thermal sprayingspecific rules but establishes general rules for the control of unsafe and
unhealthy elements.
1.5.3.1
Noise and Noise Level

Noise is an unneeded and objectionable sound. Excess noise reduces
productivity, slows reaction times, and causes tension, hearing
impairment, and nervousness.
Noise level is a measurement of sound wave energy (pressure). The
standard unit of sound measurement is decibels (dB). See Table 1-3 for
safe exposure times at different noise levels.
Thermal Spray Noise Levels
Thermal spray processes generate high noise levels. Table 1-2 shows
typical noise levels of various environments. To verify whether a problem
exists, measure the noise and noise levels at your site.
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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
Hydrogen
w/o spray booth
w/spray booth
Powder Guns
Acetylene
(High Capacity)
w/spray booth
w/spray both & airjet cooling
Wire Combustion Guns
Acetylene
1/8 & 3/16 inch
Propane
(3.2 & 4.8 mm)
Propane & nonload hardware
Methylacetylene-propadiene gas
Plasma gun
Nitrogen - 600 A
Nitrogen/Hydrogen - 600 A
Argon - 1000 A
Argon/Hydrogen - 600 A
Argon/Helium - 600 A
Argon/Nitrogen - 1000 A
HVOF
Oxygen plus kerosene
Grit-blasting Equipment
Compressed air
Exhaust Equipment
Air
1.5.3.2
dBA
111
116
89
90
110
100
101
94
111
114
118
125
118
134
133
128
133
127
131
~126
80-85
<90
Noise Duration
Noise of sufficient intensity and duration can create physiological effects.
The louder the noise, the shorter the permissible exposure. Table 1-3
shows tolerable noise limits for various exposure times.
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Table 1-3
Tolerable Noise Limits of Various Exposure Times
Exposure Duration (Per Day)
Sound Level (dBA)

Hours
24
16
8
4
2
1
80
82
85
88
91
94
Minutes
30
15
7.5
3.75
1.88
0.94
97
100
103
106
109
112
Seconds
28.12
14.06
7.03
3.52
1.76
0.88
0.44
0.22
0.11
1.5.3.3
115
118
121
124
127
130
133
136
139
Hearing Protection
If noise at your site exceeds the limits established by OSHA in
paragraph 1910.95, entitled "Occupational Noise Exposure" of the
Occupational Safety and Health Standards, you should provide ear and
or other protection to everyone near thermal spray operations to bring the
exposure within OSHA permissible, tolerable noise levels. Limit workers'
exposure to noise according to federal standards prescribed under the
Occupational Safety and Health Act.
Protect operators, nearby workers, and transient passers-by from thermal
spray noise: at the source, during its transmission, or at the receiver.
Managing any of these can solve the noise problem. Each situation
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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. Engineering controls include: redesign equipment, relocate
equipment, change operating conditions, isolate equipment acoustically,
insulate work area, and provide operator hearing protection.
Administrative controls include planning and scheduling to reduce
exposure.
If engineering and administrative controls do not achieve acceptable noise
control, OSHA regulations allow use of suitable personal protective
equipment. This also applies while engineering and administrative
controls are being established.
Mufflers on thermal spray equipment are impractical and ineffective.
Simple baffles between the gun and nearby personnel are not effective
because noise scatters around the baffle. Specially designed sound
absorbing materials provide a 5 dB reduction to adjacent areas. Sound
absorbing materials on walls and hanging baffles can reduce nearby levels
but do not solve the problem for the operator.
Relocate Equipment
Increasing the distance between the noise source and the receiver lowers
the sound pressure level. Table 1-4 lists how increasing distance can
reduce decibels in a free field.
Table 1-4
Using Distance to Reduce Decibels
Distance from
Theoretical dBA
Source
Reduction
3 feet (1 m)
0
10 feet (3 m)
10
30 feet (9 m)
20
90 feet (27 m)
28
Isolate Equipment
Isolate noise by moving it away from affected personnel or placing the
equipment in an acoustically insulated enclosure. Praxair Surface
Technologies offers spray rooms that enclose spray operations and confine
noise. These rooms are designed to limit the noise level to specified limits
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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.
Plan and Schedule to Reduce Exposure Time
Engineering controls focus on eliminating, reducing, or containing the
noise hazard. Administrative controls attempt to reduce exposure time.
Planning and scheduling are best used where spraying is intermittent.
Usually, spraying time is a small percentage of the total job compared
with setup, surface preparation, and finishing.
If spraying time exceeds the permissible levels for noise exposure,
schedule jobs over more than one shift or day to keep exposure within
maximum limits. More than one operator can spray jobs to keep the
exposure of any one person within limits. Spraying outside of regular plant
hours can control exposure of persons near the operation. Also, rotate
personnel assignments in the vicinity of the thermal spraying operation to
control exposure.
1.5.4
Protective Clothing
When working in confined spaces, wear flame resistant clothing, and
leather or rubber gauntlet gloves. Clothing should fit snugly around the
wrists and ankles to keep sprayed materials and dust away from the skin.
For work in the open, ordinary clothing may be sufficient. However, open
shirt collars and unbuttoned pocket flaps are potential hazards. Always
wear high-top shoes and cuffless trousers that cover the tops of the shoes.
If workers will be spraying toxic materials, consult a material supplier for
information on protective clothing.
Plasma spraying generates intense ultraviolet radiation that can cause a
"sunburn" through normal clothing. When plasma spraying, wear clothing
such as thick, tightly woven wool clothing that provides protection against
radiation. Also wear appropriate eye protection. For more intense
exposure, leather capes or aluminized clothing is necessary. Take care to
attach aluminized clothing to the outside of the face shield so radiation is
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not reflected onto the face shield. Wear aluminized gloves and dark, fireretardant clothing.
Arc spraying radiation protection is similar to that for electric arc welding
and is outlined in ANSI/AWS Z49.1. Some arc spraying guns are
equipped with an arc shield that protects the operator from direct exposure
to the arc. Also use a helmet if any parts of the body are exposed to direct
arc radiation or if exceptionally reflective substrates are being sprayed.
1.5.5
Confined Spaces
Spaces such as a closed tank, boiler, pressure vessel, or ship compartment
are considered confined spaces. Review AWS F3.2, Recommended Safe
Practices for the Preparation for Welding and Cutting of Containers
and Piping That Have Held Hazardous Substances, if the confined
space previously held combustible materials.
Work in confined spaces requires ventilation. See the standards referred
to in "Compressed Gas Cylinders" in section 1.4.1 of this manual for
ventilation requirements. When you are thermal spraying in any confined
space, keep the gas cylinders out of the work space.
1.5.5.1
Rapid Emergency Exit

If operators must enter a confined space through a small opening, provide
the means for rapid emergency exit. If operators are using safety belts and
life lines for this purpose, attach them to the operator's body so they will
not jam in a small exit space. Station at least one attendant trained in
rescue work outside the confined space at all times and verify this person's
ability to remove the operator from the confined space if an emergency
should occur.
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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. Evaluate
oxygen level inside the confined space with oxygen monitoring
equipment. The amount of contamination to which an operator is exposed
during spray operations depends on many factors. Consider the following
factors when selecting ventilation systems for operator safety:
Volume of space in which the operation is performed

Number of spray/abrasive blast units operating in that space
Sources of hazardous fumes, gases, or dusts (varies depending on
material sprayed)
Heat generated by the spraying process
Presence of volatile solvents
Where thermal spraying operations are incidental to general operations,

apply local exhaust ventilation to the spray areas to prevent contamination
of the general work area.
Carefully maintain individual respiratory protective devices. Clean and
disinfect devices before transferring them between employees (see ANSI
Z88.2).
Provide mechanical ventilation for operations not performed in the open or
in a properly designed and ventilated room. Ventilation equipment
usually consists of motor driven portable exhausters with flexible piping
or ducts that remove dust rapidly and allows operators suitable visibility.
A ventilation system does not preclude the need for respiratory protection
devices. See "Respiratory Protection," section 1.5.2, for recommendations
on protective devices and filtration systems.
When thermal spraying on a machine tool such as a lathe, mount an
exhaust hood at the end of the carriage so that it travels with the gun,
exhausting dust and fumes into the dust collector. Aim the gun so the
sprayed material enters the face of the hood. An average lathe hood is
about 2 ft2 (0.2m2) and the velocity of air entering the opening should be
at least 200 feet/minute (1 m/s). The hood opening design should eliminate
turbulence along the sides that could force spray dust into the operator's
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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. In automatic and production spraying, the entire mechanism
is often totally enclosed. Refer to "Industrial Ventilation" published by
the American Conference of Governmental Industrial Hygienists
(ACGIH).
Provide exhaust equipment for dry grinding or lapping operations
performed on sprayed coatings. Consult OSHA Occupational Safety and
Health Standard 1910.94, Ventilation.
Equip spray cabinets used for spraying small and medium size parts with
exhaust ventilation with an air velocity of 200 to 400 feet/minute (1 to 2
m/s) entering the hood opening. This is often referred to as the "face
velocity." Operate the spray equipment within the face area of the hood
and direct the spray into it. Design the cabinet to eliminate turbulent
currents. Refer to "Industrial Ventilation" published by ACGIH.
Blasting Rooms
Design and maintain separate rooms for grit-blasting and thermal
spraying. Design of a blasting room should include adequate lighting and
a dry cartridge-type ventilation system having ventilation down draft and
longitudinal air flow at a velocity of at least 80 to 100 feet/minute (0.4 to
0.5 m/s). Thoroughly investigate local, state, and federal regulations
before exhausting directly into the atmosphere. A blasting room should
include a dust collection system that satisfies all laws and local ordinances
for the type of work being done in the room.
Grit-blasting and thermal spraying will require their own independent dust
collectors. Although dry cartridge-type dust collectors are suitable for use
in both the grit blast and thermal spray environments, it is suggested to
refer to "Industrial Ventilation", a manual of recommended practice
with a compilation of research data and information on design,
maintenance and evaluation of industrial exhaust ventilation systems.
This manual is not intended to be used as law, but rather as a guide. In
addition, the NFPA guidelines should be used for the handling of metallic
and other materials.
Avoid using the grit-blasting room for thermal spraying because the dust
collectors can quickly become clogged with a combination of thermal
spray and grit dust. Also, an accumulation of metallic dust may create a
fire or an explosion hazard.
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Replace ventilation-removed air with clean, breathable air. Choose fans

that provide at least 10 air changes per minute. If your site uses portable
gasoline or diesel engines to drive ventilators, position them so that engine
exhaust cannot be drawn into the ventilating system or the intake of the
respirator air compressor.
Provide operators with respiratory protection as detailed in "Respiratory
Protection" in section 1.5.2.
Ground all fans, pipes, dust arrestors, and motors. DO NOT ground to
piping that carries fuel gas, oxygen, or other flammables or combustibles.
Run ventilation fans when operators are cleaning out booths, pipes, etc. to
prevent accumulation of dust or fumes in the system. NEVER weld or cut
while repairing any ventilation or dust collecting equipment unless the
equipment has been thoroughly cleaned.
1.6
Toxic Material
PERSONAL INJURY HAZARD:
Almost any material, in finely divided form, can damage the respiratory
system. Damage is often not sensed immediately. Take care to keep
floors, work benches, and booths free of dusty residues. Carefully clean
protective clothing to remove dust, or discard clothing after use.
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. Use respiratory protective
equipment such as fume respirators approved by the U.S. Bureau of
Mines, National Institute of Occupational Safety and Health (NIOSH), or
other approving authority.
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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.
Provide respiratory protection and adequate ventilation wherever the fume
and dust concentration is above the threshold limit (see "Threshold Limit
Valves" in section 1.6.6).
1.6.4
Tin and Zinc

Usually encountered in the forms of their oxides and not considered toxic,
tin and zinc may cause violent illness, including coughing, headache and,
particularly in the case of zinc oxide fumes, nausea, vomiting, chills,
fever, muscle and joint pain, and marked thirst. (In the case of zinc oxide,
the effect has been known as "brass founder's ague," "brass chills," "zinc
fever," or "metal fume fever.") Temporary short term immunity can be
developed.
Prevention consists of adequate ventilation and proper respirators (see
"Respiratory Protection" in section 1.5.2 and "Confined Spaces" in section
1.5.5). Preclude from the work any operators with pulmonary disease or
those who continue to suffer discomfort even with proper ventilation and
respirator measures.
1.6.5
Solvents
The radiation generated by plasma or arc spraying causes rapid
decomposition of some solvent vapors into noxious and toxic gases, even
at considerable distance from the arc. Slow extraction of the part from the
solvent cleaning tank can reduce this problem. When spraying vapordegreased parts, take extra care to see that all solvent (vapors or liquid
films or drops of solvent caught by pockets and crevices) is removed prior
to thermal spraying.
The ultraviolet radiation from plasma and arc spraying generates airborne
ozone. The amount of ozone produced may exceed the maximum
allowable concentration in confined spaces. Excess ozone production
should be avoided.
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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. Consult a current TLV list
concerning the maximum allowable concentration of toxic material
allowed.
Conduct air sampling to determine the ventilation requirements for
operations involving the previously listed materials. When less toxic
metals are sprayed, the concentration of dust or fumes in the work area
must not exceed the TLV for eight-hour exposure. Provide respiratory
protection devices and exhaust ventilation when the dust or fume
concentration is sufficiently high to cause operator discomfort even when
the appropriate TLV is not exceeded.
1.7
Safety Standards
In addition to the contents of this chapter, a variety of industry
publications contain safety standards. See the related publications list on
page vii.
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Section 2
Equipment Description
This chapter covers the following:
System components
Specifications and features for system components
Figure 2-1 Cutaway Diagram of Electric Arc Thermal Spray Process

Wire Guides
Wire In
Atomizing
Air In
Wire In
Arc Shield
Air Cap
2.1
System Components
As shown in Figure 2-2, the BP400 Arc Thermal Spray System consists of
the TCV 400 power source, PF400R wire control console, and the BP400
gun. The TCV 400 supplies AC control power and DC power to the
PF400R wire control console that pushes two oppositely charged
metalizing wires through coaxial cables to the BP400 gun.
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Figure 2-2 System Components
System Components
2.2
BP400 Gun
PF400R Wire Control Console
TCV 400 Power Source
System Overview
Designed with flexibility in mind, the Model BP400 Electric Arc Thermal
Spray System accommodates a wide variety of surface modification needs.
Lightweight and portable, the system can be used in hand-held and robotic
applications. Simple to operate, the BP400 hand-held mode offers a onetouch, point and shoot trigger. For robotic or manipulator mounting, a
single electrical closure provides complete system on/off control.
The BP400 push-wire delivery minimizes maintenance of the wire-drive
system and reduces the weight of the system. The gun contains no moving
drive components. Plus, the BP400 needs no adjustments to the air cap or
front wire guides, so repeatable, high-quality coatings are easy. All
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standard BP400 thermal spray system components meet stringent CE

requirements.
The BP400 output rating of 400 A at 100% duty cycle makes it the most
productive electric arc spray system in its class. Along with high
deposition rates, the BP400 also offers excellent arc stability at very low
spray rates, ensuring high quality coatings even at 50 A or less.
2.3
Component Features
The component features are described beginning below.
Figure 2-3 BP400 Spray Gun
2.3.1 BP400 Gun Features

Lightweight (less than 3 lbs., 1.36 kg.) and durable, with a simple
interface to the wire control console, the BP400 gun features:
Issued: 08/13
Arc shield
Self-aligning air cap
Full-function point and shoot trigger
14 gauge (1.6 mm) standard hardware
Optional 14 gauge (1.6 mm) high-velocity kit
Optional 11 gauge (2.3 mm) hardware
Optional Fan Spray conversion kits
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Figure 2-4. TCV 400 Power Supply
2.3.2 TCV 400 Power Source Features
NOTE:
400 A, 36 v 100% duty cycle
For more information about the TCV 400 power supply, refer to the separate
Bulletin (1.1.101.9) and Operators Manual for that equipment.
PF400R Control Console shown with optional accessories

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2.3.3
2.4
PF400R Wire Control Console Features
Control panel (1) with: digital voltage and amperage meters, separate
voltage and amperage controls (remote from power source) burn-back
control for trouble-free starts
Wire jog switch (2) for wire feeding without engaging contactor
Emergency stop button (3)
Synchronized dual wire feeding with a four-roll drive system for each
side (4)
1/4 HP permanent magnet gear motor electric wire drive (5)
14 gauge (1.6 mm) standard hardware
Optional wire spool covers (6)
Optional 11 gauge (2.3 mm) hardware
Specifications
Table 2-1 System Specifications
Wire Diameter
Capability
Weight
Dimensions
Weight
Electrical Input
Dimensions
BP400 Gun
17 ga. (3/64 inch [1.1 mm])
14 ga. (1/16 inch [1.6 mm])
2 mm (5/64 inch)
11 ga. (3/32 inch [2.3 mm])
Less than 3 lb. (1.4 kg) without cables
PF400R Wire Control Console
16.5 inch (419 mm) high x 13 inch
(330 mm) wide x 33 inch (840 mm.) deep
85 lb. (39 kg)
115 VAC, 60 Hz
Power Source
Height 27.5 (70 cm) without casters 36.35 (92.3cm) with
casters.
Width
22 (59 cm)
Depth
Weight
Electrical Input
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32 ( 82 cm)
383 lb (174 kg)
220/400 V, 50 Hz
230/460 V, 60 Hz
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2.5
BP400 System Options
Separately purchased options enable you to configure your system to suit

specific requirements.
Issued: 08/13
High-Velocity Conversion Package, 14 GA (1.6 mm) (P/N 0910400):

provides concentrated air pattern and increased particle velocity.
Fan Spray Conversion Package, 14 GA (1.6 mm) (P/N 0910405):

provides wide spray patterns for covering large areas for 14 GA (1.6
mm) wire.
Fan Spray Conversion Package, 11 GA (2.3 mm) P/N 0910405):

provides wide spray patterns for covering large areas for 11 GA (2.3
mm) wire.
11 GA (2.3 mm) BP400/PF400R Conversion Package (P/N 0910407):

provides parts necessary for converting BP400 gun and PF400R wire
control console to 11 GA (2.3 mm) wire.
BP400 Extension Guns: designed for inside-diameter and close-up

spraying. Extension guns are available in 12-inch (305 mm) and 24inch (610 mm) lengths. Straight and 90-degree angle spray
configurations are available.
Tube Mill Line Tracker Control: designed to ensure uniform coating

thickness where varied line speeds are common (requires modified
PF400R wire control console).
Wire Spool Cover: keeps dirt and other contaminants out of the wire
barrel. This protection helps to prevent electrical shock and eliminates
the need for a wire stand. Part numbers for spool covers: Right Spool
Cover - P/N 05000071; Left Spool Cover - P/N 05000070.
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Section 3
Installation
This chapter covers the following:
Siting the equipment

Receiving and handling
Installing the equipment
Always observe safe practices and follow the procedures as described.
3.1
Location
Verify that the utilities described in Chapter 2 are convenient to the
system. Position the unit so that all interconnecting cables terminate
without strain. The PF400R feeder can be placed on top of the power
source, nearby on the floor, or attached to a nearby wall. Place the TCV
400 power supply and the PF400R within 10 feet (3 m) of the operating
position of the BP400 gun (standard length cables).
3.2
Receiving And Handling

Before moving the unit, carefully inspect for any shipping damage.
Purchaser must file any claims for loss or damage incurred in transit with
the carrier. Praxair will supply a copy of the bill of lading on request if
occasion to file a claim arises. Always provide the model description and
serial number of this equipment when you request information.
1. Remove the packing crate top and side panels.
2. Remove any packing material and parts containers from around the
TCV 400 power source, and then remove the bolts fastening the
power source to the shipping skids.
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3. Position a forklift rated for at least 500 pounds (227 kg) capacity
underneath the system power supply ensuring there are no
obstructions prior to lifting the system and power supply.
4. Use the fork lift truck to lift TCV 400 with attached castor assembly
just high enough to clear the shipping skid supports under the power
supply and, SLOWLY back the lift truck away from the crate.
5. Once the TCV 400 is clear of the crate, carefully move the fork lift
truck to move the TCV 400 to its operating location.
6. Remove the packing crate top and side panels from around the
PF400R Wire Control Console.
7. Remove all packing material and parts containers from around the
wire control console.
8. Have two workers lift the PF400R Wire Control Console out of its
crate and install it to its power supply.
9. Open the shipping container containing the BP400 Gun and remove
the gun and any parts containers.
10. Install the gun and any additional parts, cables, or hoses to the
system's operating location.
3.3
Installation
ELECTRIC SHOCK HAZARD: Do not touch live electrical parts.
Shut the unit down, disconnect the input power, and use
"lockout/tagging procedures" on the power source before making
any connections. Lockout/tagging procedures consist of:
padlocking line disconnect switch in open position,
Removing fuses from the fuse box, or
Shutting off and red-tagging circuit breaker or other disconnecting
device.
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3.3.1 Connect Compressed Air Source to PF400R

1. Connect 1/2-inch diameter, customer-supplied hose between the air
regulator on back of PF400R wire control console and a customersupplied, coalescing type air filter on a compressed air supply. The
filter should have 99.97% efficiency at 0.3 to 0.6 micron particles.
2. Verify that the hose or pipe bringing compressed air to the filter is at
least -inch inside diameter.
3.3.2 Connect PF400R Console to BP400 Gun
Keep coaxial cables between the PF400R wire control console and the
BP400 gun as straight as possible. If the coaxial cables must be curved
around an object, make a long radius curve.
See Figures 3-1, 3-2, 3-3, and 3-4, and make wire control console-to-gun
connections:
1. Connect the atomizing air hose (P/N 05000659-10) between the
BP400 gun and the atomizing air connector on the PF400R wire
control console.
2. Coaxial cables (P/N 05005233-10) have a removable inner plastic
liner. Pull the inner liners trough the cables until 2 inches (50.8 mm)
of liner material extends from the gun connections of the cables.
3. Insert the exposed portion of the inner liner into the coaxial cable
connection on the back of the BP400 gun and push forward until it is
firmly seated in the connector. Maintain forward pressure on the inner
liner, attach the threaded end of the coaxial cable to the connector, and
tighten. Repeat for the second cable.
4. Move to the wire control console end of the cables, and cut off excess
inner liner, leaving 1/4-inch (6.4 mm) of liner extending beyond each
cable end.
5. Open the PF400R wire control console side doors. Insert the coaxial
cable into the socket on the front of the PF400R wire control console.
Push and twist the cable into drive roll assembly holes until coaxial
cable nut contacts drive roll assembly. Turn the hold-down thumb
screws to secure coaxial cables in position.
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Figure 3-1 Wire Control Console to Gun Connection

Coaxing Cable to
Gun, Positive
Coaxial Cable to Gun
Negative
Atomizing Air Line to Gun
for Line Tracker Assembly
(optional)
Control Cable to Gun
6. Connect the plastic voltage sensing plugs on the coaxial cables to the
plastic voltage sensing receptacles inside the PF400R wire control
console. This connection is an automatic sensing circuit that detects
whether voltage sensing is at the gun or the TCV 400 power source.
7. Connect the BP400 control cable to the gun cable connector on the
PF400R wire control console.
ELECTRIC SHOCK HAZARD: Do not touch live electrical parts.

Shut down the TCV 400, disconnect input power, and use
"lockout/tagging procedures" on power source before making any
connections. Lockout/tagging procedures consist of
- padlocking line disconnect switch in open position,
- removing fuses from the fuse box, or
- shutting off and red-tagging circuit breaker or other
disconnecting device
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Figure 3-2. Gun Connections From Wire Control Console
1. BP400 Spray Gun Head

2. Atomizing Air Line Extension
(Optional)
3. Atomizing Air Line (Control Cable
is below Air Line)
4. High Amperage Coaxial Cables
3.3.3
Connect TCV 400 Power Source to Wire Control Console
DO NOT use lock washers of any type when connecting the power
cables to the TCV 400. Using a lock washer on a conducting
terminal can create a high-resistance connection, cause sparking,
and damage the power supply. Tighten the connector nuts very
securely to ensure good contact.
Figure 3-3 Gun Connections From Feeder

1. Compressed Air Input Line,
Atomizing Air Line
2. High Amperage Input Cable
Power Supply (Negative)
3. Control Cable to Power Supply
4. High Amperage Input Cable
from Power Supply (Positive)
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1. Attach the red positive and black negative power cables to the power
source as directed in the TCV 400 operator's manual.
2. Insert the positive power cable in the red (positive) cam-lock socket
on the rear of the PF400R wire control console. Twist one-quarter turn
to secure.
3. Insert the negative power cable in the black (negative) cam-lock
socket on the rear of the wire control console. Twist one-quarter turn
to secure.
4. Carefully insert the control cable into the EPIC 25-pin connector on
the TCV 400 and snap the lock lever over to secure.
5. With one hand, insert the other end of the control cable into the
consoles corresponding connector. With the other hand, pull the lever
on the receptacle of the control console until it clicks into a locked
position.
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Figure 3-4 Diagram of Hose to Cable Connections
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Notes
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Section 4
4.1
Operation
Operating Parameters
An operating parameter is a group of settings, such as amperage, current,
and air pressure that, used together, produce a desirable coating. Factors
that affect the coating quality include:
Surface preparation
Part cooling
Overspray control
Hardware selection
Wire characteristics
Gun and part manipulation.
Only qualified and trained operators should be permitted to operate
thermal spray equipment.
4.2
Surface Preparation
Surface preparation enhances bonding and usually involves de-greasing and

roughening. De-greasing removes organic contaminants which impede bonding.
Roughening increases surface area, to augment bond strength.
4.2.1
De-greasing and Cleaning

Organic contamination from handling, cutting, machining, rolling,
casting, etc. weakens or prevents thermal spray coating adhesion.
Organics directly prevent adhesion, by either:
Masking the surface or

Vaporizing and affecting the cooling and wetting
characteristics of the sprayed droplets
Ultrasonic cleaning is not always practical. Large parts and

structures are often washed or pressure blasted with steam or hot
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water. Porous substrates such as cast iron are commonly baked at

450F (232C) for an hour prior to grit blasting, to destroy most
organic contaminants. The baked part then can be grit blasted,
rinsed and coated.
4.2.2
Roughening Methods
Roughening is commonly done by grit blasting with aluminum
oxide or various other media such as silicon carbide, glass, various
slag materials, iron, steel, etc. Roughness is expressed in terms of
micro-inches or micrometers and as a statistical average, e.g., 125
micro-inches AA (arithmetic average) or CLA (centerline
average).
Recommended surface roughness is 125 to 400 RMS.
Roughness alone does not determine whether a surface is adequate

for coating. Roughness frequency (peaks per inch) is equally
important. A coarse profile, that is, one that is less densely
populated or had a lower frequency of peaks, is not the best anchor
pattern for coating.
Morphology- shape of the blasted surface- is also important.
Angular surface features (the result of using angular grit) provide
more surface area. Crushed shot, though necessary for some
applications, produce a more rounded surface profile.
Replace the blasting medium when it becomes dull, fractured,
or contaminated. Because coating bond strength is closely
related to surface cleanliness, the grit-blasting equipment used
for thermal spray coating preparation should not be used for
general cleaning. Make sure the air supplied to the grit blast
equipment is clean, oil-free, and dry.
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4.2.3
Factors to Consider
Grit
Choice of grit is driven by cost, availability, and technical
considerations. A few guidelines can help prevent coating or
substrate failures.
Some materials tend to embed in the substrate surface acting as a
stress riser and initiating fatigue failure. Silicon carbide and glass
display this substrate-contaminating characteristic. Aluminum
oxide, or alumina, s a preferred overall grit choice.
Residual grit causes other problems as well. Siliceous materials,
such as sand and glass, can react with the substrate at high
temperatures. Iron and aluminum alloys form eutectic
compositions with silicon. The lower melting points of eutectic
compositions can be a problem because operating temperatures of
the substrates increase. Carefully select a blast medium that is
compatible with the coating system and its intended operating
environment.
If ceramics are used for blasting prior to the application of a fusible
or laser-clad coating, ceramic residue can act as a stop off,
preventing or weakening the bond. Steel or iron grit is preferred for
fusible coating applications.
Expensive blast media, like alumina, may be cost-prohibitive
where the grit cannot be recovered or recycled in process. Grit
throughput under normal blasting conditions is several hundred
pounds per hour. Slag from copper or iron smelting is often used
for structural work because of its low cost.
Other Grit-blasting Variables
Other variables to consider are air pressure, nozzle size (I.D. or
inner diameter),standoff distance, and angle of attack.
Air pressure and nozzle size determine grit velocity. Common
nozzle size is a -inch (6 mm) nozzle. Generally, air pressure is
fixed as a process parameter, and, as the nozzle wears (increasing
the inner diameter), velocity drops. Consequently, nozzle inner
diameter becomes a Quality Control point for the process. Use a
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simple go/no-go plug gauge for the I.D. to keep the grit blast
process in check.
Much grit blasting is done manually, so stand-off and angle
become variables. Fortunately, these variables are reasonably
error-tolerant. Variations of 1 inch (2.54 cm) in stand-off and
several degrees of angle are not usually critical. Blasting is
generally done perpendicular, or 90, to the surface. For some
materials and blast media, moving 5 to 15 off-axis minimizes grit
embedding.
To achieve a desired surface roughness, changing grit size is more
effective than varying pressure. Higher pressures produce slightly
higher roughness values but also increase embedment and substrate
interface hardness. Changing the grit size slightly yields greater
surface roughness control with fewer negative effects.
Alternate roughening techniques exist besides (and sometimes in
place of) conventional grit blasting. Machining can roughen a
surface in preparation for coating. Rough threading, knurling,
embossing, and so on are used to disrupt the substrate surface.
These techniques are decades old and still have some merit, but are
not recommended for use with the BP400. Undercutting a shaft
reduces its cross-sectional area, its strength, and creates notches or
stress risers. Modern engineering safety factors may not be as great
as they were when these techniques were introduced. High strength
materials, induction hardened steels, and so on may have a greater
susceptibility to fatigue, and higher design loads and RPMs in
newer equipment increase the possibility of fatigue.
Special Considerations
Take care when grit blasting a notch-sensitive material such as
titanium. Shot peen the surface prior to grit blasting. This sets up a
compressive residual stress in the surface, which often offsets the
negative effects of grit blasting. Peen with glass beads or metallic
shot as the application dictates.
4.2.4
Masking
Often the sprayed coating must be confined to a specific area of the

part, requiring masking for both grit blasting and spraying. Metal
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or silicone rubber masking is best suited for production

applications.
Tooling fabrication costs are offset by eliminating the handmasking operation. Graphite, marking ink, or other parting
compounds on the tooling decreases clean-up time and extends
mask life. Traditional masking mediums such as electrical glass
tape and teflon-impregnated glass tape perform poorly in thermal
spray applications, but they are sufficient for grit blasting.
Do not use welding anti-spatter or anti-stick compounds for masking.
They may run or char when heated. Avoid tapes with low-temperature
adhesives that can char or outgas, contaminating the coating and
substrate.
4.3
Part Cooling
Use cooling jets to provide a stream of gas or dry air at or near the point of
impingement of the coating stream on the substrate. The gas or air cools
the substrate and blows away unmolten particles and smoke (overspray).
Choose the cooling gas based on the material being sprayed. Use argon or
nitrogen for readily oxidized materials. Choose argon with materials such
as titanium, which forms a nitride easily Carbon dioxide can be a cooling
gas, or dry air may be used if oxides are not a concern.
4.4
Gun Manipulation
Surface speed, pitch, standoff, and angle of impingement are significant
variables in producing a coating with desired characteristics.
Generally, a gun surface speed of about 1200 in/min (0.5 m/sec) is
desirable for most applications. The ideal surface speed is one that creates
deposits of approximately 0.001 in/pass (25.4 microns/pass) for metallic
and coarse materials and 0.0005 in/pass (12.7 microns/pass) for ceramic
and fine materials. This thickness buildup ate decreases residual stress,
increases maximum thickness buildup, and decreases porosity. Adjust
traverse speed as required to obtain the desired buildup.
Pitch or increment is the step or feed of the gun motion associated with
traverse. Generally a pith or increment of 0.125-0.200 inch (3-5 mm) per
revolution is desirable Adjust pitch to prevent striping or "barber poling."
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Stand-off is the distance from the front of the gun to the surface of the part
being sprayed. It is usually that point where the particles are hot enough to
form the coating while the heat transfer from the gun to the part is as low
as possible. BP400 gun standoff ranges from 7 to 10 inches (178 to 254
mm). Spray stream should be perpendicular (within +/- 15 degrees) to the
part surface.
4.4.1
Atomizing End Point

On thermal spray guns used with the BP400 system, the end points
are where the wires are atomized into spray. On extension guns,
such as that shown in Figure 4-1, the end points are exposed.
ELECTRIC SHOCK HAZARD:

Never touch the end of the BP400 gun or any extension gun used
with the BP400 system when it is energized.
Figure 4-1 BP400 Spray Gun (Left) And Optional Extension (Right)
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4.5
Control Console
PF400R wire console controls are on the front panel of the unit as shown
in Figure 4-2.
Figure 4-2. Wire Console Controls, Described Below
4
1
2
3
5
6
8
7
9
10
14
11
12
13
1. Power Source Switch Light: illuminates when you energize the power
source.
2. Spray Light: illuminates when the BP400 gun power trigger is
pressed.
3. Power Reset Button: resets power to the PF400R control unit after the
stop button has been pulled out.
4. Voltage Meter: displays the voltage at the power source.
5. Voltage Control: regulates the voltage supplied by the power source.
Voltage control can be adjusted while spraying. Turn the voltages
control clockwise to increase voltage setting, or counterclockwise to
decrease voltage setting.
6. Jog Switch: actuating the momentary contact JOG switch completes
the wire feed motor circuit without actuating the gun trigger switch.
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7.
8.
9.
10.
11.
12.
13.
14.
The JOG switch feeds wire without energizing the remote contactor or
air solenoid.
Amperage Meter: displays the amperage at the power source.
Amperage/Wire Speed Control: wire drive speed determines the
amperage for a given wire. Turn the amperage/wire speed control
clockwise to increase amperage and wire drive speed. Turn the
amperage control counterclockwise to decrease amperage and wire
drive speed. Amperage can be adjusted while spraying.
E-STOP: press to lock out the power to the BP400 gun and PF400R
control unit. The Master Control Relay (R1) works with the
Emergency Stop system and is designed to shut down the system in
case of power loss to the control unit or power supply. The Master
Control Relay circuit prevents the unexpected restart of the system
when power is restored. Before restarting the system, pull the E-STOP
button fully out to restore power to the PF400R control unit.
Atomizing Air pressure gauge: shows atomizing air pressure in psi
kPa.
Atomizing Air Control: the atomizing air control is on the regulator on
the rear of the PF400R control unit. Increase atomizing air pressure by
lifting the locking ring on the regulator and turning the control
clockwise. Turn adjustment control counterclockwise to decrease
atomizing air pressure. Push locking ring down to lock pressure
setting.
High Amperage Coaxial Cable (Negative)
Control Cable
High Amperage Coaxial Cable (positive)
4.5.1
Miniature Air Regulator
The miniature air regulator, located inside the PF400R control unit,
controls the air volume flowing through the coaxial cables to the
gun. The regulator is factory-set at 45 psi (310 kPa); it should not
need readjustment. If adjustment is necessary, pull the lock ring up
and turn the adjustment knob to the correct setting. Push the lock
ring down to lock the air flow setting.
4.5.2
BP400 Gun Power Trigger
Pulling the BP400 gun trigger activates the air solenoid, remote
contactor, and wire-feed drive motor.
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Never touch the end of the BP400 gun or any extension gun used
with the BP400 system when it is energized.
4.6
Installing and Threading the Wire Spool

With coaxial cables installed between the wire control console and gun,
install the wire spools as described below:
1. Depress the alignment screws towards one another on spindle support
ring in order to release mechanism to insert wire reel (see Figure 4-3).
Figure 4-3. Aligning the wire spool spindle support arm
2. Slide the wire spool onto the hub so the wire feeds off the bottom of
the spool.
3. Rotate the spool until the hole in the spool aligns with the pin on the
spool hub. Slide the spool the rest of the way onto the hub until it sits
against the hub's back flange.
4. Return the wire spool spindle support ring to the secure position
(see Figure 4-4).
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Figure 4-4. Mounting the Spool
5. Open the wire control console's side doors. Loosen the wire drive roll
pressure adjustment knobs and pivot the knobs free of the gear covers
(as shown in Figure 4-5).
Figure 4-5. Feeder Drive Rolls
Pivot
Knob for
Adjusting
Drive Roll
Pressure
Drive
Rolls
Direction of
Wire Travel
6. Cut off the bent wire on each wire spool and straighten at least 2 feet
(610 mm) of wire by hand.
7. Check the spool hub tension by slowly pulling wire toward the gun.
Wire should unwind freely, but the hub tension should keep the wire
taut and prevent backlash when the pull on the wire stops. To adjust,
loosen or tighten the hex nut on the end of wire reel spindle (see
Figure 4-5).
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Figure 4-6. Nut for Adjusting Wire Spool Tension
Unscrew end of spindle

counter clockwise to
expose hex nut tension
adjustment
8. File and smooth the tips of both wires, then feed wire through the
flexible wire guides up to the drive rolls.
PERSONAL INJURY HAZARD: Always file and smooth the tip of
the wire before feeding the wire through the flexible wire guide. If
the wire tip is not filed and smoothed, it can puncture the liner and
damage the coaxial cable. A damaged coaxial cable can explode and
cause injury.
9. Pivot the drive roll gear cover away to expose the drive gears (see
Figure 4-5). Feed wire into the coaxial cable for about 4 inches (102
mm) beyond the wire drive rolls. Repeat for the second wire.
10. Pivot the gear covers onto the drive gears.
11. Pivot the pressure adjustment knobs onto the gear covers. To secure,
turn knobs clockwise until they are snug.
Over-tightening the pressure adjustment knobs flattens the wires,
causing an irregular arc. Test drive roll pressure after wire has
been fed through the coaxial cable to the gun: Grip the wire (after
the point where it comes off the spool) between thumb and
forefinger. If the drive rolls slip when moderate resistance is applied
to the wire, tighten them slightly. Retest and adjust until the drive
rolls firmly pull the wire.
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NOTE: visible wire shavings on the bottom of the wire control console
enclosure is an indication of drive roll slippage. To reduce slippage,
tighten the drive roll pressure adjustment knobs.
12. Close and latch the wire control console side doors to satisfy the door
interlock switches. Now you can jog wire to the gun.
13. Press the JOG switch to advance the wires through the coaxial cables
to the gun. Stop the wires when they extend approximately 1/2-inch
(13 mm) from the gun wire guides.
4.7
System Check-out
1. Verify that input power is OFF and the BP400 system is properly
connected according to the instructions in Section 4.4
2. Mount and thread wire according to the instructions in Section 4.6.
3. Place the gun in a properly protected and ventilated enclosure and aim
the nozzle into the dust collector.
4. Energize the collector.
5. Supply a minimum of 90 psi (621 kPa) compressed air to the wire
control console.
6. Pull the atomization air regulator adjustment lock ring up and adjust
the regulator to 80 psi (552 kPa). Push the lock ring down to secure
adjustment.
7. Supply input power to the TCV 400 power source and turn the
POWER switch to ON. The POWER light will illuminate.
8. Verify that the BP400 gun is pointed in a safe direction and that all
personnel are clear of the spray area.
9. Pull out the wire control console E-STOP button and press the RESET
button to energize the wire control console.
10. Press the JOG button to advance wire from the wire control console to
the BP400 gun until both wires extend out from the front of the gun.
ELECTRIC SHOCK HAZARD: Pulling power trigger switch
causes wires to arc together. DO NOT pull the power trigger switch
while jogging wire. Never touch the end of the BP400 gun or any
extension used with the BP400 system when it is energized.
11. Cut each wire off as close to the air cap as possible.
12. Adjust the voltage of the wire control console to the desired level.
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13. Place properly shaded protection over eyes.

14. Press the BP400 gun trigger.
15. Adjust voltage/amperage and atomizing air pressure to desired levels
and observe the gun spray behavior. See Chapter 5 for further
adjustments, maintenance, and troubleshooting information.
16. Release the gun trigger or press the red E-STOP button to stop
spraying.
4.8
System Shutdown
For emergency air and power shutdown:
1. Release the BP400 gun power trigger switch. This cuts off the
air and electrical power at the gun.
2. Press the E-STOP button on the wire control console to cut off
power to the console.
To do a normal shutdown of the BP400 system:
1. Release the gun trigger power switch.
2. Push the E-STOP button on front of the PF400R wire control console.
3. Turn the power switch on the TCV 400 power source to OFF.
4.9
Spray Settings
Table 4.1
Voltage Requirements
(approximate +/- 1-2 volts)
Wire Type
Steel
Zinc
Bronze/SS/NickelCopper Alloy
Aluminum
Al/Bronze
BondArc
Molybdenum
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Load Volts
When Spraying
Open Circuit Volts Before Spraying Set at
24-26 volts
18-19 volts
26-28 volts
100 Amps
27 volts
20 volts
29 volts
200 Amps
29 volts
21 volts
31 volts
300 Amps
31 volts
22 volts
33 volts
26-28 volts
29-32 volts
29-32 volts
34-35 volts
29 volts
31 volts
32 volts
36 volts
31 volts
33 volts
33 volts
37 volts
33 volts
35 volts
35 volts
38 volts
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95 MXC
73MXC & 74MXC
34-35 volts
29-32
36 volts
32 volts
37 volts
33 volts
38 volts
36 volts
Table 4-2
Spraying Distances
Type of Work
Small to light work
Average Distance
10-12 in. (254-305 mm)
AMPS
100-150
Medium work
Heavy work
8-10 in. (203-254 mm)

6-8 in. (152-203 mm)
250-350
350-480
Flash coat
1-3 in. (25.4-76 mm)
100-175
Applications
Synthetic materials
(i.e. plastics, etc)
Sheet Steel
3 in. (76 mm) diameter
and larger shafts
Any materials
Table 4-3
Atomizing Air Pressure Settings
Type Coating
Flash
Machinable
Hard
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Atomizing Air Range

20-40 psi (138 to 276 kPa)
50-60 psi (345 to 414 kPa)
80-150 psi (552 to 1034 kPa)
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Section 5
5.1
Maintenance & Troubleshooting

Maintenance
Regular maintenance is critical to safe and accurate operation of the
BP400 Electric Arc Thermal Spray System. Usage and shop conditions
may affect the frequency and type of maintenance.
If you are cleaning the wire control console unit with compressed air, do
not allow the air to rotate drive rolls at high speed. High rotational speed
can damage drive rolls.
Develop a maintenance schedule and follow it to ensure that tasks are
performed at the correct intervals. See the suggested schedule below.
Table 5-1 Suggested Maintenance Schedule
Procedure
Inspect BP400 gun and PF400R wire control console for
broken, cracked or loose parts (repair or replace as required).
Use wood dowel to clean spatter and foreign material from
around gun shield & disc.
Clean grease and dirt from components. Dry moisture from
any electrical parts and/or cables.
Check gun front wire guides for enlarged or out of round
inside diameters, and other damage (replace as required).
Check shield for damage and/or broken areas.
Blow compressed air through flexible wire guides and
coaxial cables to remove metal chips or dirt.
Inspect all hoses and cables for cuts, cracks, abrasion, or
frayed insulation, especially at fitting attachment points
(replace as required).
Inspect all precautionary labels for readability and replace
them as required.
When Due
Each Start-up
Performed By
Operator
Each Start-up
Operator
Each Start-up
Operator
Each Start-up
Operator
Each Start-up
Each Start-up
Operator
Operator
Each Start-up
Operator
Each Start-up
Operator

The arc spray wire and all metal parts in contact with it are
energized while spraying. Disconnect and "lockout/tagout" input
power before working on system. Avoid contact between any
ungrounded portion of the gun and the spray booth chamber.
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BURN HAZARD:
Hot surfaces can cause severe burns. Allow a cooling period before
servicing equipment.
Cleaning the BP400 system with compressed air generates high
noise levels and causes particulates to become airborne. Wear
proper hearing and eye protection and restrain coaxial cables in a
safe direction away from personnel and equipment while cleaning
with compressed air.
If you are cleaning the wire control console unit with compressed air,
do not allow the air to rotate drive rolls at high speed. High
rotational speed can damage drive rolls.
5.1.1
BP400 Gun Parts

The BP400 gun arc shield, air cap, and front wire guides become
worn with use. Inspect them regularly and replace worn parts as
necessary as described in the following procedure and shown in
Figure 5-1.
1. Unscrew and remove the arc shield from BP400 gun. Remove the
air cap and inspect for wear. If necessary, discard worn parts and
replace with new ones.
2. Using a small pliers, turn each wire guide counterclockwise to
loosen, then unscrew and remove the wire guides by hand. Inspect
the guides for wear.
3. Use compressed air to blow out any metal chips or dirty that
accumulated in the wire guide connections.

Using compressed air for cleaning generates high noise levels and
causes particulates to become airborne. Wear proper hearing and
eye protection.
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Figure 5-1 Standard Setup: BP400 Gun Air Cap and Wire Guide Replacement
4. Re-install the existing wire guides or install new wire guides.

- Thread each guide into position, and then turn it clockwise
by hand until snug.
- Use small pliers to tighten the wire guides into position.
DO NOT OVERTIGHTEN the wire guides. Over-tightening does
not improve performance and can strip the threads in the BP-400
gun head. A stripped-out gun head cannot be repaired and must be
replaced.
5. Re-install the air cap and arc shield. Be careful not to overtighten the arc shield: tighten only by hand to prevent damage
to the BP400 gun. Check out the alignment of the air cap and
tips after tightening them.
5.1.2
Coaxial Cables and Liner
Coaxial cables, and the liner that goes inside them, wear with use
and periodically must be replaced. Check coaxial cables and liners
for wear on a regular schedule and replace when necessary.
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1. Disconnect the coaxial cable (P/N 05005233) from BP400 gun

and from PF400 control unit.
Do not attempt to install the liner without removing the cable from the
gun. While this method may work in some instances, it does not ensure
proper seating and compression of the liner.
2. Remove the old liner by pulling it out of the coaxial cable from
BP400 gun end. Discard liner.
3. Unscrew the gray wire guide (P/N 05001166) from the PF400R
control unit end of coaxial cable.
4. Lay the coaxial cable out straight and install the new liner by
pushing it through the cable.
5. When the liner is pushed fully through the cable, use a tubing
cutter to trim the liner: allow 2 inches (51 mm) of liner to
extend from the gun connection end of the cable and allow
inch to extend from the control unit end.
6. Re-install the gray wire guide onto the PF400R control unit end
of the co-axial cable.
7. Connect the treaded end of the coaxial cable to the connection
on the back of the BP400 gun.
Allowing the liner to extend 2 inches (51 mm) from the gun end of the
cable "pre-loads" the liner and compresses it against the gun head fitting.
This reduces liner "creep," a condition that can cause erratic feeding.
8. Reconnect coaxial cable to PF400R control unit.
5.1.3
Air Filter
1. Turn off the air supply and bleed air from the air line.
2. Remove the bowl guard, transparent bowl, and air filter.
3. Clean the transparent bowl and parts with warm water and mild
detergent solution only. Never use a solvent to clean the bowl.
4. Dry parts and blow out the internal passage of the air filter
assembly with clean, dry compressed air.
Using compressed air for cleaning generates high noise levels and
causes particulates to become airborne. Wear proper hearing and
eye protection.
Issued: 08/13
Page 52

Operators Manual
_____________________________________________________________________________________________________________________
5. Blow compressed air through the filter element from inside to

outside to dislodge surface contaminates.
6. Inspect all parts carefully.
7. Reinstall the air filter and transparent bowl. Be sure the bowl is
properly seated on the gasket.
8. Reinstall the bowl guard.
5.1.4
Speed Control Unit
The speed control unit controls the wire drive motor. For optimum
results, do not adjust the factory settings unless directed by an
authorized service representative. During trouble-shooting, you
may be asked to adjust the factory settings. These include linear
acceleration, linear deceleration, adjustable current limit (torque),
I.R. compensation, the maximum for high-speed operation, and the
minimum starting speed.
5.1.5
Timer
The Timer (T1) serves as a wire burn back, and is adjustable

between 0.1 and 1.0 second. During system shut-down, the timer
can permit the air solenoid and remote contactor to remain
activated after wire feeding stops.
During system start-up, the 0.0 setting is recommended for most arc
spray applications.
5.2
Troubleshooting
Occasionally, unexpected problems that affect equipment operation may
arise. Use the circuit diagram at the end of this Section (Figure 5-2), with
Table 5-2 while troubleshooting your system.
This section pertains to units that have been installed according to the
procedures described in Chapter 3 of this manual.
Only qualified personnel should perform troubleshooting.
Table 5-2 lists problems that may develop and recommends possible
remedies. If doing any of the recommended procedures does not solve the
problem, contact a TAFA customer service representative. In all cases of
equipment malfunction, the manufacturer's recommendations should be
strictly followed.
Issued: 08/13
Page 53

Operators Manual
_____________________________________________________________________________________________________________________
Table 5-2 Troubleshooting Chart
CONDITION
No air at gun.
Gun does not produce an

arc. No voltage at gun.
PROBABLE CAUSE
Main air supply off.
Power supply off.
Atomizing regulator
improperly set.
Loose control cable
connections.
Incorrect hose connections.
Air solenoid inoperative.
Air disc plugged.
REMEDY
Check main air supply.
Check power supply.
Set atomizing air pressure (see
Section 4-4).
Tighten control cables.
Damaged control cables.
Check control cables (see Section 32).

Turn on power supply
Adjust voltage control. For copper
and conductive wires, start with
maximum voltage, then reduce to
proper setting after arc start (see
Section 5-4)
Check and replace if necessary.
Power supply off.

Voltage control set too low.
Gun does not produce an

arc. Voltage at gun.
Gun does not maintain

steady arc.
No control power (gun

switches inoperative).
Issued: 08/13
Voltage control
potentiometer.
Damaged PC board.
Front wire guides
maladjusted.
Wire not feeding from one
or both sides.
Improper voltage level.
Front wire guides dirty or
worn.
Spool hub tension nuts on
control stand too tight.
Speed control
potentiometer.
Relay R2.
Power supply input fuses.
Jumper links incorrectly set.
Line input fuses.
115 VAC circuit breakers.
Relays R1, R2, or Timer T1.
Check hose connections.

Replace air solenoid or coil.
Remove and clean disc.

Adjust front wire guides.
Check wire tension and wire guides.
Set voltage level.
Clean or replace wire guides.
Adjust hub tension.
Check potentiometer. Replace if
necessary.
Check R2. Replace if necessary.
See power source operator's manual.
Check R1, R2, and T1. Replace if
necessary.
Page 54

Operators Manual
_____________________________________________________________________________________________________________________
CONDITION
No control power (gun
switches inoperative)
Cont.
Gun will not feed or
feeds wire erratically.
Water in atomizing air

stream.
Inadequate air pressure
gauge readings.
Voltage meter and/or

amperage meter do not
work.
PF400R Control will not
jog.
Wire feeds without gun
or jog switch pressed.
Issued: 08/13
PROBABLE CAUSE
Control cable toPF400R or
power source was misinstalled.
POWER RESET switch.
REMEDY
See Chapter 2.
Wrong size wire guides.

Wire binding in front wire
guide due to dirt.
Wire tensioning nuts on
spool holders too tight.
Worn motor brushes.
DC Speed Control.
Dirty air filter.
Install correct wire guides.

Blow out wire guide with compressed
air.
Adjust hub tension on spool holders
(see Section 3-4).
Replace brushes.
Replace DC Speed Control unit.
Clean air filter (see Section 5-1).
Improperly adjusted
pressure regulator.
Damaged pressure gauge.
Inadequate line pressure
into system
Adjust regulator to appropriate

setting.
Repair or replace gauge.
Consult nearest Factory Authorized
Service Rep. Of the compressor
manufacturer.
Edge connector loose.
Secure connector.
Wire connections.
Check meter terminals; reconnect as
necessary.
Voltage or Amperage meter. Check meters; replace if necessary.
Jog switch malfunction.
Check switch; replace if necessary.
Wire speed or amperage
Adjust speed control clockwise for
control not properly set.
correct wire feed rate.
Slow speed potentiometer
Turn speed control ON. Adjust
on DC speed control unit
SLOW speed potentiometer counter
out of adjustment.
clockwise until motor stops running.
Page 55

Operators Manual
Figure 5-2 BP400 System Schematic, 640005 rev F
Issued: 08/13
Page 56

Operators Manual
_____________________________________________________________________________________________________________________
Section 6
Parts List
This chapter reviews the standard parts of the BP400 Electric Arc Thermal Spray
System.
Figure 6-1 BP400 Electric Arc Thermal Spray System
1 BP400 Arc Spray Gun

2 PF400R Wire Control Console
3 TCV 400 Power Supply
Issued: 08/13
Page 57

Operators Manual
_______________________________________________________________________________________________________________________________________________________________________________________-______________________________________________________________________________________
Figure 6-2 PF400R Wire Feeder Assembly, 9104030 rev U
Issued: 08/13
Page 58

Operators Manual
_______________________________________________________________________________________________________________________________________________________________________________________-______________________________________________________________________________________
Figure 6-3 PF400R Wire Feeder Assembly, 9104030 rev U
Issued: 08/13
Page 59

Operators Manual
_____________________________________________________________________________________________________________________
Figure 6-4 PF400R Wire Control Console, 91040302, rev J
Issued: 08/13
Page 60

Operators Manual
_____________________________________________________________________________________________________________________
Table 6-1: PF400R System Parts

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
PART #
05000652
05000316
05007140
05000292
07000017
200048
05000802
07000018
07000016
05000107
07000618
05000349
05000478
251257
251113
251233
250124
NA
05004785
05007071
05003020
05003012
05004730
05004810
610346
07000058
400025
02509100
05000555
05000225
210333
251110
480106
05000603
200077
0240275
220065
DESCRIPTION
Screw, Sltd. Hex Washer Hd, 1-32 x 3/8
Panel, Top Wrapper
Label, Warning, Arc Welding, "CE"
Motor, DC, with Transmission
Nut, Hex 1/4-20
Washer, Lock, 1/4
Label, Praxair Logo
Washer, Flat, 1/4 inch
Screw, HHCS, 1/4-20 x 1/2
Latch, Door, Plastic
Screw, SHSS, 1/4-20 x 1/4
Shaft, Motor, Extender
Key, Square
Module, Led, Green, 120 VAC Integrated
Contact, Block
Operator, Push Button, Illuminated, Mom, Green
Socket, Lamp, 120 VAC
NA
Panel, Front, PF400R
Panel, Front, Faceplate, Lexan, PF400R
Light, Indicator, 120 VAC
Lens, Flat Bezel, Green
Amp, Receptacle
Bushing, Snap In Nylon
Jumper, E-Stop
Rivet, Aluminum, Pop
Gauge, Pressure, 0-160 PSI, Dual Readout
Adapter, Pipe, Brass, 1/4 MPT - 1/2-20 MT
Connector, Brass, Tube, 1/8 TU - 1/8 FP
Tubing, Nylon
Fitting, Reducing, Bushing
Operator, E-Stop, Push/Pull
Knob, Plastic
Switch, Cap, Black
Screw, BHCS, 6-32 x 1/4
Connect, Base, Panel Mount
Tubing, 1/4, Poly
QTY
6
1
1
1
14
24
2
32
6
2
4
2
2
1
1
1
2
1
1
2
2
1
2
1
2
1
1
1
2 FT
1
1
2
1
3
1
17.25 IN
NA = Not Applicable
Issued: 08/13
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_____________________________________________________________________________________________________________________
ITEM
43
44
45
46
47
48
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
Issued: 08/13
PART #
210345
220100
410267
05000488
05000236
05000431
200602
05000209
05000306
200482
07000117
05000322
05000214
05000636
05000525
05000321
07000296
07000064
05000224
05002145
200038
200050
07000207
05000487
05000464
05000465
05000424
05000452
01400903
05000007
200287
05000468
200553
540198
200221
05000313
05000480
05001057
05006095
DESCRIPTION
Tee, Male Run, 1/4 NPT 1/4 Tube one Touch
Tubing, 1/2OD x 3/8 ID Soft Nylon
Regulator, Air
Harness, Wiring not available for purchase
Nipple, Pipe, Close, Brass, 1/4 MPT
Terminal, Cover, Strip, w/Clips
Screw, BHSCS, 8-32 x 1/2
Valve, Solenoid
Support, Solenoid
Bolt Hex, 1/4-20 x 1
Screw, HHCS, 5/16-18 x 2
Tee, Pipe, Brass, 1/2 FPT x 1/2 FPT x 1/4 FPT
Elbow, Pipe, Street, Brass, 1/4 MPT x 1/4 FPT
Washer, Flat, 5/16
Bushing, Flanged, 5/16, Insulator
Nipple, Pipe, Long, Brass, 1/2 MPT x 1-1/2
Screw, Hex Head Cap, 1/4-10 x 3/4
Nut, Hex, 5/16-18
Connector, Tube, Brass, 1/8 TU x 1/4 FPT
Tee, Pipe, Brass, 1/4 MP x 1/4 MP x 1/4 MP
Nut, Hex, 3/8-16
Washer, Lock, 3/8
Washer, Flat, Brass
Cable, Internal, 2/0 x 17PF
Camlock, Female, Receptacle, Red
Camlock, Female, Receptable, Black
Panel, Back, PF400R
Nut, Locking, Brass, 1/8 FP
Camlock, 11/14 Ga.
Tubing, Teflon, 1/4 OD x 1/8 ID
Screw, BHCS, 4-40 x 3/8
Filter, Fluid, Regulator, W/O Gauge, 0-160 psi
Washer, Lock #8, Internal Tooth
Label, Serial #, CE
Screw, RHMS-S, 8-32 x 3/8
Circuit Board, Motor Speed Control
DIN Rail
Terminal Block, End Clamp
Relay, 1PDT, 120vAC
QTY
1
7.5 IN
1
1
1
1
4
1
1
4
4
2
2
8
8
3
2
4
1
1
4
4
6
2
1
1
1
2
2
2 ft
8
1
6
1
2
1
1
1
2
Page 62

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_____________________________________________________________________________________________________________________
ITEM
83
84
85
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
116
117
118
119
120
122
123
124
Issued: 08/13
PART #
05004586
05000458
210754
05002723
05000454
07000312
0M053706
07000024
07000184
05000348
05000352
05001527
05000455
07000122
210619
05000476
05000390
05000347
200049
410018
05000649
05000569
05000077
05000310
200111
07000295
05000425
05003904
0M079626
210125
210416
210244
251105
05002983
251106
05007108
05007082
05001688
DESCRIPTION
Relay, Tie Down
Relay, 2PDP, Time Delay
Fitting, 1/2 MPT 1/2 Tube 45 Elbow, One-Touch
Fuse, 5 Amp
Plate, Electrical Mounting PF400R
Spacer, #8 x 1/4 Long
Drive Roll, 14 Gauge U Groove
Screw, Socket Head Cap, 1/4-20 x 3/8
Washer, Flat, 3/16 #12
Gear, Spur
Guide, Center Wire, 14-11 Ga., Nylon
Drive Roll Assembly, W/O Rolls RHS
Guide, Rear Wire
Screw, SHCS, 3/8-16 x 1 1/4
Fitting, Elbow, 1/4 OD Tub 1/8 NPTM
Insulator, Drive Roll
Spacer Block, Aluminum
Drive Roll Assembly, W/O Rolls LHS
Washer, Lock, 5/16
Switch, Pressure, Mod260
Support, spool, assembly PF400R, Rev A
Stand-Off, 5/16 ID x 7/8 OD x 3/4 High
Skid, Base
Foot, Gray Rubber, 1 OD x 3/4 High
Bolt, Hex, 1/4-20x1-1/2
Screw, Hex Head Cap, 1/4-20 x 5/8
Panel, Bottom, PF400R
Gauge, Pressure, 0-160 psi/kPa
Screw, Mach. Fil. Pan Head 10-32 x 5/8
Reducer, 1/8 NPT 1/4 NPT pipe to pipe
Coupling, 1/8 FNPT
Union, bulkhead, 1/2 NPT plate, Legend, E-Stop
Legend, Yellow, Blank
Relay, 2PDT, 120VAC
Latch, Mounting, PB Switch
Label, Gas Schematic (CE) Style Feeder
Switch, Interlock, DC Voltage
Molex Crimp Pin
QTY
6
1
2
1
1
4
8
2
2
2
2
1
2
2
2
2
2
1
4
1
1
4
1
4
4
8
1
1
24
1
1
1
1
1
2
1
2
4
Page 63

Operators Manual
_____________________________________________________________________________________________________________________
ITEM
125
126
127
128
129
131
133
134
Issued: 08/13
PART #
05001686
200192
251112
240638
07000628
00700060
400101
400102
DESCRIPTION
Molex, Plug
Screw, SHCS, 8-32 x 1, SS
Contact, Block, Screw Terminal
Encl, Terminal for Interlock Switch
Washer, Flat, #8, Black Nylon
Nut, Hexagonal 6-32
Meter, Digital, 0-200 VDC, Panel Mount, PF400
Meter, Digital, 0-750 A, Panel Mount, PF400
QTY
2
4
3
2
4
1
1
1
Page 64

Operators Manual
_____________________________________________________________________________________________________________________
Figure 6-5 Spool Support, 05000649, rev B
Table 6-2: Parts List for Spool Support

ITEM
1
2
PART #
05006531
05000062
3
4
5
6
7
05000063
05000064
05000065
05000066
07000319
8
9
10
07000068
05000069
05006205
Issued: 08/13
DESCRIPTION
Spindle, Support, W/O Threaded Rod
Washer, Fiber,.6250X1/8 ThickX1.5
Rev O
Washer, Brake, Spindle Assembly
Hub, Spool, Spindle Assembly
Washer, Flat, Keyed, 1.5 inch diameter
Spring, Compression
Washer, Flat, .6406 ID X .075 THK X
1.0 OD
Nut, Hex, 5/8-11
Ring, Spool Retaining
Shaft, Spool Support
QTY
1
4
4
2
2
2
2
1
2
1
Page 65

Operators Manual
_____________________________________________________________________________________________________________________
Figure 6-6 Drive Roll Assembly, 5001527, rev F
Issued: 08/13
Page 66

Operators Manual
_____________________________________________________________________________________________________________________
Table 6-3: Parts List for Drive Roll Assembly

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
PART #
05001015
05000630
07000475
05000631
05000632
05000633
05000634
0M166338
05000637
0M166071
05000639
05000640
05000641
05000636
05006486
0M166072
05000352
DESCRIPTION
Housing, Wire Drive PF400, R.H.
Gear, Spur Insulated w/Bearing
Screw, Hex Head Cap, 1/4-20 x 1-1/4
Pin, Fastener 0895
Washer, Cupped, 21/64
Spring, Compression
Knob, Tension Adjustment
Lever, Mtg-Pressure Gear #1
Knob, 0797
Lever, Mtg-Pressure Gear #2
Pin, Hinge
Pin, Cotter Hair 0.042 x 15/16
Pin, Roll 3/16 x 1
Washer, Flat, 0.3125"
Screw, Thumb 1/4-20 x 1/2 Nylon
Spacer
Center Wire Guide (not shown)
QTY
1
4
4
2
2
2
2
1
1
1
1
2
2
1
2
2
1
Table 6-4 Drive Rolls

ITEM
1
2
3
4
5
6
7
Issued: 08/13
PART #
05000628
0M053701
0M053704
0M053706
0M132960
0M132961
05000346
DESCRIPTION
14 Gauge, V groove, Drive Rolls
17 Gauge, U groove, Drive Rolls
2 MM, U groove, Drive Rolls
14 Gauge, U groove, Driver Rolls
2 MM, V.K. groove, Drive Rolls
11 Gauge, V.K. groove, Drive Rolls
11 Gauge, U groove, Drive Rolls
QTY
8
8
8
8
8
8
8
Page 67

Operators Manual
_____________________________________________________________________________________________________________________
Figure 6-7 BP400 Electric Arc Thermal Spray Gun, 9104003-XX, rev L
Issued: 08/13
Page 68

Operators Manual
_____________________________________________________________________________________________________________________
Table 6-5: Parts List for BP400 Gun, 9104003-XX, rev L

ITEM
11
12
13
14
15
16
17
17a
17b
17c
19
PART #
05006194
05000019A
05000392
05004604
01402800
02509100
05000655-XX
05000656-XX
07000199
05000531
07000006
DESCRIPTION
Shield
Aircap, Alumina, Cloverleaf
Tips, Front Wire, 14 GA. (1.6 mm)
Gun, BP400 Head Only
Bracket, Mounting
Adapter, Hex Br. 1/4 MPT x 1/2-20
Handle Assembly with Control Cable (X = Length)
Control Cable, Trigger (XX = Length)
Washer, Lock, Handle
Screw, Handle
Screw, Socket Head Cap 1/4-20 x 0.5
QTY
1
1
2
1
1
1
1
1
2
2
7
Table 6-6 BP400 Conversion Kits

PART #
0910400
0910405
0910406
0910407
DESCRIPTION
KIT BP400 HIGH VELOCITY CONVERSION, 14 GA (2.3 mm)
KIT, BP400 FAN SPRAY CONVERSION, 14 GA (2.3 mm)
KIT, BP400 FAN SPRAY CONVERSION, 11 GA (1.6 mm)
KIT, BP400 / PF400R CONVERSION to 11 GA (1.6 mm)
QTY
EA
EA
EA
EA
Table 6-7 Set Up For Spraying 85/15 Zinc - Aluminum

The following is a list of components needed with instructions on how to install them properly.
PART #
5007116
M132960
M053704
DESCRIPTION
Wire Guide BP400 2mm 85/15
Drive Roll 2mm VK-Grove
Drive Roll 2mm U-Groove
QTY
2
4
4
1. Install the wire guides (5007116) as normal. Remove and replace.

2. Remove the front drive rolls and replace with new 2mm U-Groove Rolls (M053704) Two on the
right and two on the left.
3. Remove the rear drive rolls and replace with the new VK-Groove Rolls (M132960) Two on the
right and two on the left.
4. Install wire, adjust roll tension, and replace all safeties before starting to spray.
Issued: 08/13
Page 69

Operators Manual
_____________________________________________________________________________________________________________________
Figure 6-8 BP400 High Velocity Conversion Kit, 14 GA (2.3 mm), 910400 rev F
Issued: 08/13
Page 70

Operators Manual
_____________________________________________________________________________________________________________________
Table 6-8: Parts List for BP400 High Velocity Conversion Kit, 14 GA (2.3 mm), 910400
ITEM
1
2
PART #
05004734
05000981
DESCRIPTION
AIR CAP, BP GUN, HIGH VELOCITY
GUIDE, WIRE BP400
QTY
1.0 EA
2.0 EA
OPTIONS:
05004762
05004813
07000035
VALVE, OPTIONAL (Remove existing fitting)

EXTENDER, AIR NOZZLE, OPTIONAL
O-RING, EXTENDER, OPTIONAL
1.0 EA
1.0 EA
1.0 EA
Issued: 08/13
Page 71

Operators Manual
_____________________________________________________________________________________________________________________
Figure 6-9 BP400 Fan Spray Conversion Kit, 14 GA (2.3 mm), 910405 rev D
Issued: 08/13
Page 72

Operators Manual
_____________________________________________________________________________________________________________________
Table 6-9: Parts List for BP400 Fan Spray Conversion Kit, 14 GA (2.3 mm), 910405
ITEM
1
2
3
PART #
05004737
05004738
05000981
Issued: 08/13
DESCRIPTION
AIR CAP, BP400 GUN, FANSPRAY, 14 GA
RING CLAMP, AIR CAP, FANSPRAY
GUIDE, WIRE BP400
QTY
1.0 EA
1.0 EA
2.0 EA
Page 73

Operators Manual
_____________________________________________________________________________________________________________________
Figure 6-10 BP400 Fan Spray Conversion Kit, 11 GA (1.6 mm), 910406
Issued: 08/13
Page 74

Operators Manual
_____________________________________________________________________________________________________________________
Table 6-10: Parts List for BP400 Fan Spray Conversion Kit, 11 GA (1.6 mm), 910406
ITEM
1
2
3
PART #
05004993
05004738
05004992
Issued: 08/13
DESCRIPTION
AIR CAP, BP400 GUN, FANSPRAY, 11 GA
RING CLAMP, AIR CAP, FANSPRAY
GUIDE, WIRE, BP400, 11 GA
QTY
1.0 EA
1.0 EA
2.0 EA
Page 75

Operators Manual
_____________________________________________________________________________________________________________________
Figure 6-11 BP400 / PF400R Conversion Kit to 11 GA (1.6 mm), 910407D
Issued: 08/13
Page 76

Operators Manual
_____________________________________________________________________________________________________________________
Table 6-11: Parts List for BP400 / PF400R Conversion Kit to 11 GA (1.6 mm), 910407
ITEM
1
2
3
4
PART #
05004992
05007862
05000346
0M132961
Issued: 08/13
DESCRIPTION
GUIDE, WIRE, BP400, 11 GA
AIR CAP, 11 GA
DRIVE ROLL, 11 GA, U-GROOVE
DRIVE ROLL, 11 GA, VK-GROOVE
QTY
2.0 EA
1.0 EA
4.0 EA
4.0 EA
Page 77

Operators Manual
_____________________________________________________________________________________________________________________
Figure 6-12 Coaxial Cable Parts (5005233 rev G)
Issued: 08/13
Page 78

Operators Manual
_____________________________________________________________________________________________________________________
Table 6-12: Parts List for Coaxial Cable from Gun to PF400R Wire Control Console
ITEM
1
2
3
PART #
05001166
05004649
05000007
DESCRIPTION
Guide, FR WR 11 ga to 14 ga LF/RT BP
Cable, Coaxial without liner***
Tubing, Teflon, 1/4 x 1/8 ID*
QTY
1
1
**
* Alternate part number for nylon liners: 05006881

**Tubing length equals cable length plus 1 foot
***See Table 6-6 for complete coaxial cable assembly
Table 6-13: Parts List for other Hoses & Cables

ITEM
1
2
3
4
5
Issued: 08/13
PART #
610691-XX
05002298-XX
05000660-XX
05006577-XX
05000659-XX
DESCRIPTION
Control Cable (Power Supply - Console)
High Amperage Power Lead (Negative) (PS Console)
High Amperage Power Lead (Positive) (PS Console)
Coaxial Cable Assembly (Console Gun)
Atomizing Air Hose (Console Gun)
QTY
1
1
1
2
1
Page 79

Operators Manual
_____________________________________________________________________________________________________________________
Figure 6-13 Extension, 12 Angle Parts - OPTIONAL
Issued: 08/13
Page 80

Operators Manual
_____________________________________________________________________________________________________________________
Table 6-14 Parts List for 12 Angled Extension - OPTIONAL

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Issued: 08/13
PART #
09104023
05002276
07000079
05002407
01313110
05000824
07000065
07000083
05000826
07000495
05002275
05002405
05002321
05002323
07000026
210416
05000893
05000818
02508300
05000006
02509100
05002673
05000236
05006432
07000040
07000639
07000017
200048
390039
DESCRIPTION
12" ANGLED BP400 GUN EXTENSION
NOZZLE EXTENSION
SCREW
ELBOW
GUIDE, WIRE BP400
NOZZLE ATOM AIR
NUT,HEX
SCREW
BLOCK, INSULATOR
SCREW
CLAMP, A3 EXTENSION
TUBE, ATOM AIR 12IN
TUBE, ASSY, WIRE 12IN BP LEFT
TUBE, ASSY, WIRE 12IN BP RIGHT
SCREW
COUPLING, PIPE
ADAPTOR,PIPE
TUBE, ASSY, ATOM AIR 12" STRAIGHT
COUPLING,THRD BR
HOSE, AIR ATOMIZING A3, 15 FT
ADAPTOR,PIPE
VALVE, BALL
NIPPLE,PIPE CLOSE BRASS
PLATE, MOUNTING BRACKET
SCREW
SCREW
NUT,HEX
WASHER, LOCK
SHRINK TUBING
QTY
EA
1.0 EA
1.0 EA
1.0 EA
2.0 EA
1.0 EA
1.0 EA
2.0 EA
2.0 EA
2.0 EA
2.0 EA
1.0 EA
1.0 EA
1.0 EA
2.0 EA
1.0 EA
1.0 EA
1.0 EA
1.0 EA
1.0 EA
1.0 EA
1.0 EA
1.0 EA
1.0 EA
2.0 EA
2.0 EA
4.0 EA
4.0 EA
10.0 IN
Page 81

Operators Manual
_____________________________________________________________________________________________________________________
Figure 6-14 Extension, 24 Angle Parts - OPTIONAL
Issued: 08/13
Page 82

Operators Manual
_____________________________________________________________________________________________________________________
Table 6-15 Parts List for 24 Angled Extension - OPTIONAL

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Issued: 08/13
PART #
09104024
05002276
07000079
05002407
01313110
05000824
07000065
07000083
05000826
07000495
05002275
05002406
05002320
05002322
07000026
210416
05000893
05000817
02508300
05000006
02509100
05002673
05000236
05006432
07000040
07000639
07000017
200048
390039
DESCRIPTION
24" ANGLED BP400 GUN EXTENSION
NOZZLE, BP/A3, EXTENSION
SCREW
ELBOW,MACH,BR A3 EXT
GUIDE, WIRE BP400
NOZZLE, BP/A3, ATOM AIR
NUT,HEX
SCREW
BLOCK, INSULATOR, A3,BP
SCREW
CLAMP, A3 EXTENSION
TUBE, ATOM AIR 24IN A3
SCREW
COUPLING,PIPE BR
ADAPTOR,PIPE BR
TUBE,ASSEMBLY,ATOMIZING
COUPLING,THRD BR
HOSE, AIR ATOMIZING A3, 15 FT
ADAPTOR,PIPE BR
VALVE, BALL
NIPPLE,PIPE CLOSE BRASS
SCREW
SCREW
NUT,HEX
WASHER, LOCK
SHRINK TUBING
QTY
EA
1.0 EA
1.0 EA
1.0 EA
2.0 EA
1.0 EA
1.0 EA
2.0 EA
2.0 EA
2.0 EA
2.0 EA
1.0 EA
1.0 EA
1.0 EA
2.0 EA
1.0 EA
1.0 EA
1.0 EA
1.0 EA
1.0 EA
1.0 EA
1.0 EA
1.0 EA
1.0 EA
2.0 EA
2.0 EA
4.0 EA
4.0 EA
10.0 IN
Page 83

Operators Manual
_____________________________________________________________________________________________________________________
Figure 6-15 Extension, 12 Straight Parts - OPTIONAL
Issued: 08/13
Page 84

Operators Manual
_____________________________________________________________________________________________________________________
Table 6-16 Parts List for 12 Straight Extension - OPTIONAL

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Issued: 08/13
PART #
09104021
01313110
02508300
05000818
05002656
05000826
07000026
07000065
07000083
05002323
05002321
05006432
07000040
07000017
200048
DESCRIPTION
12" STRAIGHT BP400 GUN EXTENSION
GUIDE, WIRE BP400
COUPLING,THRD BR
TUBE, ASSY, ATOM AIR 12"
BLOCK, INSULATOR
SCREW,
NUT,HEX
SCREW
SCREW
NUT,HEX
WASHER, LOCK
QTY
EA
2.0 EA
1.0 EA
1.0 EA
1.0 EA
2.0 EA
4.0 EA
1.0 EA
2.0 EA
1.0 EA
1.0 EA
1.0 EA
4.0 EA
4.0 EA
4.0 EA
Page 85

Operators Manual
_____________________________________________________________________________________________________________________
Figure 6-16 Extension, 24 Straight Parts - OPTIONAL
Issued: 08/13
Page 86

Operators Manual
_____________________________________________________________________________________________________________________
Table 6-17 Parts List for 24 Straight Extension - OPTIONAL

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Issued: 08/13
PART #
09104020
01313110
02508300
05000817
05002656
05000826
07000026
07000065
07000083
05002322
05002320
05006432
07000040
07000017
200048
390039
DESCRIPTION
24" STRAIGHT BP400 GUN EXTENSION
GUIDE, WIRE BP400
COUPLING,THRD BR
TUBE,ASSEMBLY,ATOMIZING
BLOCK, INSULATOR
SCREW
NUT,HEX
SCREW
SCREW
NUT,HEX
WASHER, LOCK
SHRINK TUBING
QTY
EA
2.0 EA
1.0 EA
1.0 EA
1.0 EA
2.0 EA
4.0 EA
1.0 EA
2.0 EA
1.0 EA
1.0 EA
1.0 EA
4.0 EA
4.0 EA
4.0 EA
30.0 IN
Page 87

Operators Manual
_____________________________________________________________________________________________________________________
Table 6-18 Tips for BP 400 and Extension Gun

PART #
DESCRIPTION
05000391
05000392
05003654
05006314
05008108
05002693
05007116
05007802
05007424
05000981
05004992
05006101
05007147
01313110
01313120
01323110
01323120
05007259
11ga Standard
14ga Standard
17ga Standard (nspr)
2mm Standard
1/8" Standard
14ga Standard Extended Life
2mm Standard 85/15 Z/A Wire
11ga Standard 85/15 Z/A Wire
1/8" Standard 85/15 Z/A Wire
14ga High Velocity/Fan
11ga High Velocity/Fan
2mm High Velocity/Fan
14ga High Velocity/Fan Extended Life
14ga Hard Wire
14ga Soft Wire
11ga Hard Wire
11ga Soft Wire
2mm Slotted Soft Wire
Gun
BP400
BP400
BP400
BP400
BP400 1/8"
BP400
BP400
BP400
BP400 1/8"
BP400
BP400
BP400
BP400
ID
ID
ID
ID
ID
Table 6-19 Air Caps and Nozzles for BP 400 and Extension Gun
PART #
05000019A
05007078
05003179
05007141
05006194
05007234
05004734
05004737
05004993
05007325
05004738
05007494
05007862
05007863
05000982
05000824
05002656
Issued: 08/13
DESCRIPTION
Air Cap 14 ga & 11 ga ceramic (pink) use with std. tips
Air Cap Aluminum
Air Cap 11ga Ceramic use with zinc
Air Cap 14ga Aluminum Conical
Air Cap Shield
Air Cap Retainer Shield
Air Cap 14ga High Velocity
Air Cap w/screws 14ga Fan Spray (use with 05004738)
Air Cap w/screws 11ga Fan Spray (use with 05004738)
Air Cap 14ga Fan Spray w/o Shield (use with 05004738)
Air Cap Retaining Ring (use with fan spray caps)
BP Air Cap Shield 11ga
Air Cap BP Aluminum 11ga w/ Shield
Air Cap BP Aluminum 11ga w/o Shield
Shield BP Automotive
Nozzle 11ga (brass)
Nozzle (Nylatron)
Gun
BP400
BP400
BP400
BP400
BP400
BP400
BP400
BP400
BP400
BP400
BP400
BP400
BP400
BP400
BP400
Extension
Extension
Page 88

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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Model BP400

Arc Spray System

Praxair Surface Technologies, Inc.

Model BP400 Arc Spray System

Read This Before Using

Thermal spraying is powerful technology. Do not use equipment

Who should use Thermal Spray Equipment?

Understand what to do before you do it!

Model BP400 Arc Spray System

Generic Thermal Spray Process

This manual and related documentation, especially:

Technical bulletins included with or referred to in this manual. This

Guidelines and practices your specific site has established as standard

About This Manual

This manual presents information about setting up, operating, maintaining,

Model BP400 Arc Spray System

A procedure or setting that will produce optimum results

Information that can help to operate the equipment more effectively.

Refer to the manual before doing any maintenance.

Risk of eye injury. Eye protection required.

Wear hearing protection.

Model BP400 Arc Spray System

ELECTRIC SHOCK HAZARD

HIGH TEMPERATURE HAZARD

ELECTROMAGNETIC FIELDS HAZARD

LIGHT EMISSION HAZARD

People with Heart Pacemakers Not Allowed

Model BP400 Arc Spray System

OSHA (Occupational Safety and Health Administration) establishes

Model BP400 Arc Spray System

Oxygen, CGA Pamphlet G-4, available from the Compressed Gas

Model BP400 Arc Spray System

Equipment Description ........................................................................................21

Reminder: Safety First! .......................................................................................................... 1

System Components ............................................................................................................. 21

Model BP400 Arc Spray System

Maintenance & Troubleshooting ...............................................................49

Parts List ......................................................................................................57

BP400 Electric Arc Thermal Spray System .................................................... 57

Model BP400 Arc Spray System

Figure 6-15 12 Straight Extension - OPTIONAL ............................................................. 84

Model BP400 Arc Spray System

Fire prevention and protection

Reminder: Safety First!

Model BP400 Arc Spray System

Fire Protection and Prevention

Model BP400 Arc Spray System

Safe Operating Conditions

Model BP400 Arc Spray System

Model BP400 Arc Spray System

Flame Spray and HVOF Equipment

Model BP400 Arc Spray System

Plasma and Arc Spray Equipment

Model BP400 Arc Spray System

Abrasive Blast Machine

Handling and Manipulating Equipment

Model BP400 Arc Spray System

Wire Flame Spraying (except Molybdenum)

In thermal spray operations where additional respiratory protection is not

Model BP400 Arc Spray System

Model BP400 Arc Spray System

Noise and Noise Level

Model BP400 Arc Spray System

Model BP400 Arc Spray System