Nordson Versa-Spray User manual

Versa-SprayCable-Fed
Automatic Electrostatic
Powder Spray Gun
Manual No. 31-13  P/N 108 129E
NORDSON CORPORATION AMHERST, OHIO USA

1994 Nordson Corporation
All Rights Reserved
108 129
Issued 3/94
Manual No. 31-13
Notice
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1990. No part
of this document may be photocopied, reproduced, or translated to another language without the prior written
consent of Nordson Corporation. The information contained in this publication is subject to change without notice.
Trademarks
100 Plus, Blue Box, ChromaFlex, CleanSleeve, CleanSpray, Cross-Cut, Easy Coat, Econo-Coat, Flexi-Spray,
Flow Sentry, FoamMix, Isocoil, Isocore, Iso-Flo, Nordson, PRX, Pro-Flo, RBX, Ready-Coat, Rhino, Select Coat,
Shur-Lok, Smart Spray, System Sentry, Thread Coat, Tribomatic, and Versa-Spray are
registered trademarks of Nordson Corporation.
CPX, CanWorks, Control Coat, Excel 2000, PowderGrid, Pulse Spray, SCF, Select Cure, Versa-Coat,
Versa Screen, and Package of Values are trademarks of Nordson Corporation.
Viton is a registered trademark of E.I. DuPont de Nemours and Company.
Tivar is a registered trademark of Poly-Hi Corporation.

iIntroduction
1994 Nordson Corporation
All Rights Reserved 108 129
Issued 3/94
Manual No. 31-13
Table of Contents
1. Description 1..................................................
Standard Versions 1.........................................
Options 1...................................................
2. Installation 2...................................................
Installing Optional 32mm Conical Nozzle 3......................
Air Supply 4.................................................
3. Operation 5....................................................
Start Up 5...................................................
Shutdown 6.................................................
4. Preventive Maintenance 7.......................................
Daily 7.....................................................
Periodically 7................................................
5. Troubleshooting 9..............................................
6. Disassembly and Repair 11......................................
Powder Path 11.............................................
Cleaning and Repair 12.......................................
Replacing Cable And Resistor 12..............................
Replacing Cable Assembly 12.................................
Replacing Resistor Assembly 13...............................
Replacing Electrode 14.......................................
7. Parts Lists 15..................................................
Using The Parts Lists 15......................................
Reference Numbers 15.......................................
Notes 15....................................................
Part Numbers 15............................................
Descriptions 15..............................................
Quantities 15................................................
Gun Assembly Parts List 17...................................
Resistor Service Kit 18.......................................

ii Introduction
1994 Nordson Corporation
All Rights Reserved
108 129
Issued 3/94
Manual No. 31-13
Table of Contents (contd.)
Optional Flat Spray Nozzles 19................................
2.5 mm Flat Spray Nozzle 19..................................
3 mm Flat Spray Nozzle 19...................................
4 mm Flat Spray Nozzle 20...................................
6 mm Flat Spray Nozzle 20...................................
Optional Cross-Cut Nozzles 21................................
60_ Cross-Cut Nozzle 21.....................................
90_ Cross-Cut Nozzle 21.....................................
Optional Castle Nozzle 22....................................
Optional 32 mm Conical Nozzle 23.............................
Optional 150 mm and 300 mm Lance Extensions Parts Lists 25....
Optional Deflectors and Hose Adapter 26.......................
Gun Mounting Bar 27........................................
Powder Feed Tubing 27......................................
Automatic Purge Adapter Kit 27................................
Adapter, Purge, Versa-Spray 28...............................
Low-flow Purge Adapter Inlet (Optional) 29......................
Index 31.........................................................
General Safety Precautions Manual 30-1............................
A
ppendix

Description 1
 Nordson Corporation 1994
All Rights Reserved 108 129
Issued 3/94
Manual No. 31−13
Versa-Spray Cable-Fed Automatic
Electrostatic Powder Spray Gun
The Versa-Spray Cable-Fed Automatic Powder Spray Gun is a
corona-type electrostatic powder spray gun. The gun consists of a
mounting block, extension, powder inlet body, nozzle, feed tube
adapter, and high voltage cable and resistor. High voltage is supplied to
the resistor electrode by the high voltage cable. As the powder is
sprayed from the nozzle it passes through an electrostatic corona and
picks up a charge. This gun is used with a Nordson 100 PLUS or
EXP-100 electrostatic power supply.
Figure 1. Cable-Fed Auto Gun
4 mm flat spray nozzle, 8 meter cable
4 mm flat spray nozzle, 12 meter cable
4 mm flat spray nozzle, 16 meter cable
Options which can be ordered separately and installed by the customer
include:
2.5, 3, and 6 mm flat spray nozzles
60and 90cross-cut nozzles
castle nozzle
32 and 45 mm conical nozzles
150 and 300 mm lance extensions
Also available are various sizes of deflectors for conical nozzles and a
low-flow feed tubing adapter kit. For part numbers and ordering
information, refer to the parts lists in this manual.
1. Description
Standard Versions
Options

2Installation
 Nordson Corporation 1994
All Rights Reserved
108 129
Issued 3/94
Manual No. 31−13
1. Install the gun onto a 5/8 in. (15 mm) mounting bar and secure the
mounting bar to a stationary gun stand or reciprocator arm.
WARNING: This gun can only be used with the cables listed in
this manual, and only with a 100 PLUS or EXP-100 power
supply. Unauthorized modifications or substitutions will void
your equipment warranty and any agency approvals, and
could cause personal injury or property damage.
2. Connect powder feed tubing to the tubing adapter on the bottom of
the powder inlet body.
Establish a protected path for the powder feed tubing and
electrostatic cable from the gun to the powder pump and
electrostatic power supply. Make sure that the tubing and cable
cannot be abraded, cut, or run over by heavy equipment such as
forklift trucks.
Mount gun on 5/8”
mounting bar.
Secure cable
and feed tubing to
mounting bar. Allow
slack for movement.
Install end in
power supply
multiplier well.
Install tubing
over adapter and
secure with clamp.
Figure 2. Gun Installation
2. Installation

Installation 3
 Nordson Corporation 1994
All Rights Reserved 108 129
Issued 3/94
Manual No. 31−13
The electrostatic cable should not be bent in a radius of less than 6
inches (152 mm), nor subjected to any strain. Use elastic bands or
cable ties to secure the cable and tubing to the mounting bar and
reciprocator arm, if used, so that any strain is taken up by the
tubing, not the cable.
3. Connect powder feed tubing to the powder pump. Wrap spiral-cut
tubing around the feed tubing wherever necessary to prevent it
from kinking.
NOTE: To increase powder flow and keep distribution as even as
possible, the powder feed tubing should be kept short. Ideally, the
tubing should not be longer than 26 ft (8 meters).
4. Connect the high voltage cable to the electrostatic power supply,
as described in your power supply manual. Make sure the cable
end is clean and dry before connecting.
WARNING: The electrostatic equipment in itself is safe.
However, metal objects in the spray area that are isolated
from ground accept and store an electrical charge and can
become unsafe. Ungrounded workpieces present a fire
hazard and also lose transfer efficiency. For these reasons,
all objects and the work in the spray area MUST BE
PROPERLY GROUNDED.
1. Remove the flat spray nozzle and the flat spray wear sleeve from
the gun.
2. Install the conical wear sleeve over the electrode and resistor
assembly. Be careful not to bend the electrode. DO NOT use the
conical nozzle without the wear sleeve.
3. Ensure that the O-rings are in place on the nozzle. Press the
nozzle into the end of the gun with a slight twisting motion until the
nozzle bottoms out.
CAUTION: The electrode has a very sharp tip. Install the
deflector by its edges only. DO NOT push the deflector onto
the resistor with your palm. Personal injury may result.
4. Install the conical deflector over the resistor. The deflector should
bottom out on the wear sleeve.
5. Slide the pattern adjuster sleeve onto the nozzle, with the hole in
the sleeve towards the mounting block end of the gun.
6. Slip the end of the adjuster rod under the pattern adjuster sleeve,
so that the rounded pin on the end of the adjuster rod goes into the
hole in the sleeve.
Installation (contd.)
Installing Optional 32 mm
Conical Nozzle

4Installation
 Nordson Corporation 1994
All Rights Reserved
108 129
Issued 3/94
Manual No. 31−13
Adjuster Rod
Adjuster Rod
Clip
Wear
Sleeve
Nozzle
Pattern
Adjuster
Deflector
Figure 3. Conical Nozzle Assembly
7. Press down on the adjuster rod clip until it snaps onto the gun
body. Slide the clip backward and forward a few times to make
sure it has been assembled correctly.
Powder spray systems require clean, dry operating air. Moist or
otherwise contaminated air can cause powder to clog in pump venturi
throats, feed tubing, and gun passages, and can also cause grounding
or arcing of the high-voltage electrostatic charge.
Use filter/separators with automatic drains and a refrigerated or
regenerative desiccant-type air dryer, capable or producing a 38F
(3.4C) or lower dewpoint at 100 psi (6.89 bar).
Air Supply

Operation 5
 Nordson Corporation 1994
All Rights Reserved 108 129
Issued 3/94
Manual No. 31−13
WARNING: Read and heed the warnings and cautions given
in Manual No. 30-1, General Safety Precautions for Powder
Systems and Equipment, before operating this equipment.
1. Turn ON the system electrical power and air supply.
2. Turn ON the booth exhaust fans.
3. Fill the feed hopper 2/3 full with clean, dry powder. Start fluidizing
air and adjust to the pressure recommended for your hopper
(typically 10-15 psi [0.7-1.0 bar]). Allow time for the powder to
become completely fluidized before spraying.
WARNING: Breathing finishing powders may be hazardous to
your health. Obtain and read the Material Data Safety Sheets
for the powders you are using. Wear appropriate respiratory
protection when handling or spraying powder.
4. Turn ON the electrostatic power supply main power switch. Do not
turn on the high voltage until air pressures are set.
5. Adjust pump air pressures:
Atomizing: 30 psi (2.1 bar)
Flow Rate: 20 psi (1.4 bar)
NOTE: Flow rate air pressure controls the volume and velocity of the
powder and air mixture delivered to the gun. Atomizing air pressure
controls the density (powder-to-air ratio) and velocity of the mixture.
The pressures given above are average starting points. Pressures will
vary due to required film build, line speed, and part configuration.
Adjust air pressures to obtain desired results.
6. Test spray pattern and adjust air pressures and pattern sleeve, if
used, as necessary.
7. Turn ON the high voltage at the electrostatic power supply. Adjust
to 100 kV.
3. Operation
Start Up

6Operation
 Nordson Corporation 1994
All Rights Reserved
108 129
Issued 3/94
Manual No. 31−13
8. Test spray workpieces. Adjust the air pressures and kV output to
achieve desired results.
If using a master control unit to control multiple guns and power
supplies, the power supply high voltage and main switches can be left
on after initial startup adjustments are made. Turning the master
control on will then trigger pump air and high voltage.
WARNING: When gun is being controlled by a master control
unit, turn OFF high voltage and main switches at the power
supply and ground gun electrode, before removing gun from
service for repairs.
1. Turn OFF the power supply high voltage and main switches. If
your system uses multiple guns controlled by a master control unit,
turn OFF power at the master control unit to shut down all the
guns.
2. Disassemble and clean the gun powder paths and pumps. Blow
out the feed tubing, from the pump into the booth (make sure
exhaust fans are running). Replace worn parts.
Perform daily maintenance as described in your component and system
manuals.
For information on the operation of other components of your system,
refer to their respective manuals.
Start Up (contd.)
Shutdown