Nordson Versa-Spray II Customer Product Manual
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Nordson Versa-Spray II Customer Product Manual

Automatic powder spray gun
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Versa-Sprayr II Automatic
Powder Spray Gun
Customer Product Manual
Part 107016-02
Issued 05/16
For parts and technical support, call the Industrial Coating
Systems Customer Support Center at (800) 433-9319 or
contact your local Nordson representative.
This document is subject to change without notice.
Check http://emanuals.nordson.com for the latest version
and available local languages.
NORDSON CORPORATION • AMHERST, OHIO • USA

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  • Page 1 For parts and technical support, call the Industrial Coating Systems Customer Support Center at (800) 433-9319 or contact your local Nordson representative. This document is subject to change without notice. Check http://emanuals.nordson.com for the latest version and available local languages. NORDSON CORPORATION • AMHERST, OHIO • USA...

  • Page 2: Table Of Contents

    8-13 Contact Us Notice This is a Nordson Corporation publication which is protected by copyright. Nordson Corporation welcomes requests for information, comments, and Original copyright date 1995. No part of this document may be inquiries about its products. General information about Nordson can be...
  • Page 3 Change Record Change Record Revision Date Change 05/16 Remove approval labels. Add kit information in parts list. Part 107016-02 E 2016 Nordson Corporation...
  • Page 4 Change Record Part 107016-02 E 2016 Nordson Corporation...

  • Page 5: Safety

    Regulations and Approvals Make sure all equipment is rated and approved for the environment in which it is used. Any approvals obtained for Nordson equipment will be voided if instructions for installation, operation, and service are not followed. All phases of equipment installation must comply with all federal, state, and local codes.

  • Page 6: Personal Safety

    Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation. Use only replacement parts that are designed for use with original equipment. Contact your Nordson representative for parts information and advice. Part 107016-02 E 2016 Nordson Corporation...

  • Page 7: Grounding

    Disconnect and lock out electrical power. Close pneumatic shutoff valves and relieve pressures. Identify the reason for the malfunction and correct it before restarting the equipment. Disposal Dispose of equipment and materials used in operation and servicing according to local codes. Part 107016-02 E 2016 Nordson Corporation...

  • Page 8: Safety Label

    14. Guns, feeders, booths, etc., may be cleaned with clean dry air at 1.7 bar (25 psig). If you have any questions concerning this electrostatic spray equipment, call (440) 988-9411, and ask to speak with the Powder Systems Group Technical Service Department. Part 107016-02 E 2016 Nordson Corporation...

  • Page 9: Description

    Section 2 Description Introduction See Figure 2-1. The Versa-Spray II Integral Power Supply (IPS) automatic electrostatic powder spray gun electrostatically charges and sprays organic powder coatings. The integral power supply (multiplier) (4) is available in either positive or negative polarity and is user-replaceable. The spray gun can be used with several different control units and powder pumps.

  • Page 10: Theory Of Operation

    Description Theory of Operation The Versa-Spray II control unit supplies low-voltage dc power to the voltage multiplier. The multiplier generates the high voltage needed for powder coating. The voltage generates a high-strength electrostatic field between the spray gun and the grounded part in front of the spray gun. The electrostatic field produces a corona discharge around the electrode.

  • Page 11: Gun Air Upgrade Kits

    Gun Air Upgrade Kits Five kits are available to add a diffuser and nozzle extension to a Versa-Spray II automatic powder spray gun. For spray guns used with a Versa-Spray II control unit, the following kits are available. Diffuser kit...

  • Page 12: Specifications

    Use 3-micron filter/separators with automatic drains and a refrigerated or regenerative desiccant-type air dryer that can produce a 3.4 _C (38 _F) or lower dewpoint at 7 bar (100 psi). Part 107016-02 E 2016 Nordson Corporation...

  • Page 13: Installation

    6. Hose bracket 2. 25.4-mm (1-in.) bar 5. Set screws 7. Hose adapter 3. Mounting bar Note: Refer to Gun Mounting Bar in the Options section for ordering information about the mounting bar (3). Part 107016-02 E 2016 Nordson Corporation...

  • Page 14: Gun Connections

    The hose should not be more than 8-m (25-ft) long. 3. Guns with Optional Gun Air Kit used with Versa-Spray II Control Units—Install the gun air tubing. For instructions on connecting guns with air to Versa-Spray control units, refer to the instructions shipped with the upgrade kits.
  • Page 15 9. 6-mm tube connector 2. Gun air tubing connector 6. Feed hose 10. Restrictor 3. Feed hose connector 7. 6-mm Atomizing air tubing 11. Powder pump 4. Gun cable 8. 6-mm Flow rate air tubing Part 107016-02 E 2016 Nordson Corporation...
  • Page 16 Installation Part 107016-02 E 2016 Nordson Corporation...

  • Page 17: Operation

    Keeps powder from building up on the electrode NOTE: The pressures given are average starting points. Pressures will vary according to required film build, line speed, and part configuration. Adjust the pressures to obtain the desired results. Part 107016-02 E 2016 Nordson Corporation...

  • Page 18: Shutdown

    NOTE: The following steps describe electrostatic voltage settings made on a Versa-Spray II control unit that includes AFC controls. A Versa-Spray II spray gun can be used with older Versa-Spray control units without AFC controls, but only the kV mode will be available unless the optional current limit kit is installed.

  • Page 19: Daily

    7. Set screw 2. Resistor probe 5. Optional nozzle adapter 8. Hose adapter 3. Powder inlet body 6. Flat-spray nozzle Note: Item 4 is not used on guns that have an optional nozzle adapter. Part 107016-02 E 2016 Nordson Corporation...

  • Page 20: Weekly

    Replace the multiplier, resistor, or both, if the resistance readings do not fall within the specified ranges. Refer to Continuity and Resistance Checks in the Troubleshooting section for more information. Part 107016-02 E 2016 Nordson Corporation...

  • Page 21: Troubleshooting

    This section contains troubleshooting procedures. These procedures cover only the most common problems that you may encounter. If you cannot solve the problem with the information given here, contact your local Nordson representative for help. Problem Page Uneven pattern, unsteady or inadequate powder flow...
  • Page 22 Malfunctioning IPS control unit Repair or replace the control unit. Failed resistor in optional nozzle Check resistor with a megohmmeter extension for 18−22 megohms at 500 volts. Part 107016-02 E 2016 Nordson Corporation...

  • Page 23: Continuity And Resistance Checks

    1400414B Figure 5-1 Preparing for Continuity and Resistance Checks 1. Flat-spray nozzle 4. Electrode 7. Feed hose adapter 2. Powder inlet body 5. Resistor probe 8. Set screw 3. Wear sleeve 6. Multiplier Part 107016-02 E 2016 Nordson Corporation...
  • Page 24 NOTE: This test can be made without a shorting plug. Connect all three multiplier pins together before taking a reading with a megohmmeter. Failure to do so could damage the multiplier. Contact your Nordson representative for more information. 1400415B...

  • Page 25: Resistor Resistance Check

    153 and 187 megohms at 500 volts. If the reading is out of this range, replace the resistor probe. 1400420B Figure 5-3 Resistor Resistance Check 1. Electrode 3. Resistor spring 5. Multiplier well 2. Resistor probe 4. Multiplier 6. Resistor probe cavity Part 107016-02 E 2016 Nordson Corporation...

  • Page 26: Nozzle Extension Resistor Resistance Check

    18 and 22 megohms at 500 volts. If the reading is out of this range, replace the resistor. 1400196B Figure 5-4 Nozzle Extension Resistor Resistance Check 1. Resistor holder 3. Spider/wear sleeve 4. Nozzle adapter 2. Resistor Part 107016-02 E 2016 Nordson Corporation...

  • Page 27: Gun Cable Continuity Check

    Control Unit End Pins Function Open Negative (Common) Positive (+21 Vdc) 5 Vdc Feedback 5, 6 Jumpered Table 5-2 Cable Pin Functions—Gun End Gun End Pins Function Negative (Common) 5 Vdc Feedback Positive (+21 Vdc) Part 107016-02 E 2016 Nordson Corporation...
  • Page 28 Troubleshooting Part 107016-02 E 2016 Nordson Corporation...

  • Page 29: Repair

    Powder will build up and impact-fuse on scratches. 6. If necessary, wipe the parts with a cloth dampened with isopropyl or ethyl alcohol. Do not use any other solvent. Do not immerse the assembled spray gun or parts in alcohol. Part 107016-02 E 2016 Nordson Corporation...

  • Page 30: Multiplier Replacement

    2. Loosen the set screws (1) in the gun mount (2). Remove the spray gun from the mounting bar. 3. Perform steps 1 through 4 of the Powder Path Repair procedure. Part 107016-02 E 2016 Nordson Corporation...
  • Page 31 8. Connect the gun cable, feed hose, and air tubing (if it is used) to the spray gun. 1400419B Figure 6-2 Multiplier Replacement 1. Set screws 4. Screw 6. Multiplier/resistor assembly 2. Gun mount 5. Diffuser 7. Screws 3. Hose bracket Part 107016-02 E 2016 Nordson Corporation...

  • Page 32: Resistor Replacement

    Figure 6-3 Resistor and Contact Tip Replacement 1. Contact tip 3. Resistor spring 5. Multiplier well 2. Resistor probe 4. Multiplier 6. Resistor probe cavity Note: Clean and grease items 1, 3, 5, and 6. Part 107016-02 E 2016 Nordson Corporation...

  • Page 33: Contact Tip Replacement

    4. Screw the new contact tip into the resistor probe and tighten it securely. Wipe the excess dielectric grease off the contact tip and probe. 5. Install the wear sleeve over the resistor probe. Install the powder inlet body, nozzle, and hose adapter. Part 107016-02 E 2016 Nordson Corporation...

  • Page 34: Nozzle Extension Resistor Replacement

    Figure 6-4 Nozzle Extension Resistor Replacement 1. Powder inlet body 5. Conical nozzle 8. Resistor holder 2. Nozzle extension 6. Deflector 9. Pin 3. Nozzle adapter 7. Resistor 10. Slot 4. Wear sleeve/spider/resistor holder Part 107016-02 E 2016 Nordson Corporation...

  • Page 35: Parts

    A dash (—) is used when the part number applies to all parts in the illustration. The number in the Part column is the Nordson Corporation part number. A series of dashes in this column (- - - - - -) means the part cannot be ordered separately.

  • Page 36: Automatic Gun Assemblies

    Parts Automatic Gun Assemblies NOTE: Four Versa-Spray II automatic guns are currently available. If you need to order a gun air wash extension or diffuser kit, use the Gun Air Upgrade Kits lists on page 8-4. Automatic Guns with Shur-Lok Mount See Figure 7-1.
  • Page 37 Parts 1400421B Figure 7-1 Versa-Spray II IPS Automatic Powder Spray Gun with Shur-Lok Mount Parts Part 107016-02 E 2016 Nordson Corporation...

  • Page 38: Automatic Gun With In-Line Ball Mount

    S S S SCREW, set, cone, M6 x 8, stainless steel 183549 S S S CAP, ball mount 183818 S S S BALL, pivot, Versa-Spray II gun mount 941176 S S S O-RING, silicone, 0.813 x 1.00 x 0.094 in. 982067...
  • Page 39 Parts 1401298A Figure 7-2 Versa-Spray II IPS Automatic Powder Spray Gun with In-Line Ball Mount Parts Part 107016-02 E 2016 Nordson Corporation...

  • Page 40: Service Kits

    B: See Automatic Guns with In-line Ball Mount on page 7-4 for parts in kit. Service Kit Reference Chart − Versa-Spray II Automatic Spray Guns These service kits are used to replace parts on Versa-Spray II automatic spray guns. Refer to the Options section for service kits for optional components.

  • Page 41: Resistor Holder Service Kit

    S O-RING, silicone, 0.312 x 0.438 x 0.063 in. - - - - - - S HOLDER, resistor - - - - - - S RESISTOR 245733 S GREASE, dielectric, 3-cc applicator NS: Not Shown 1400139A Figure 7-3 Resistor Service Kit Part 107016-02 E 2016 Nordson Corporation...
  • Page 42 Parts Part 107016-02 E 2016 Nordson Corporation...

  • Page 43: Options

    ION COLLECTOR KIT, ball mount Page 8-13 NOTE A: Refer to the Optional Nozzles for Versa-Spray and Versa-Spray II Guns instruction sheet for application, installation, and parts information about the nozzles and deflectors available. B: Refer to the 150-, 300-, and 450-mm Lance Extensions instruction sheet for installation and parts information for the optional lance extensions.

  • Page 44: Miscellaneous Options

    These are bulk part numbers. Order in one-foot increments. Part Description Note 900550 POWDER TUBING, Isoprene, 0.469 x 0.208 in. 900549 POWDER TUBING, Isoprene, 0.348 x 0.208 in. 900742 AIR TUBING, polyurethane, 6 mm Part 107016-02 E 2016 Nordson Corporation...

  • Page 45: Purge Adapter

    -in. ID hose NOTE A: See Figure 8-4. Optional hose adapter for use with -in. ID feed hose. AR: As Required 1400443B Figure 8-3 Purge Adapter 1400446A Figure 8-4 -in. ID Hose Adapter for Purge Adapters Part 107016-02 E 2016 Nordson Corporation...

  • Page 46: Gun Air Upgrade Kits

    Diffuser and Extension Kit See Figure 8-5. This kit adds both a diffuser and a nozzle extension to a Versa-Spray or Versa-Spray II gun without air used with a Versa-Spray II control unit. To install the components, follow the instructions included with the kit.

  • Page 47: Diffuser Kit

    Diffuser and Extension Kit Diffuser Kit See Figure 8-6. This kit adds a diffuser to a Versa-Spray or Versa-Spray II gun without air used with a Versa-Spray II control unit. To install the components, follow the instructions included with the kit.

  • Page 48: Kits For Guns Used With Versa-Spray Control Units

    Versa-Spray control units. Diffuser Kit This kit adds a diffuser to a Versa-Spray or Versa-Spray II gun without air used with a Versa-Spray control unit. Use this kit with the manifold listed in Gun Air Manifold. To install the components, follow the instructions included with the kit.

  • Page 49: Gun Air Manifold

    Options Gun Air Manifold To use Versa-Spray II automatic spray guns already equipped with diffusers and extensions with Versa-Spray control units, order the manifold listed below. Up to five automatic spray guns can be supplied with regulated air from the manifold.

  • Page 50: Nozzle Extension Kit For Guns Used With Versa-Spray Or Versa-Spray Ii Control Units

    Order the following kit to upgrade a spray gun used with a Versa-Spray or Versa-Spray II control unit. This kit adds a nozzle extension to a Versa-Spray or Versa-Spray II gun with a diffuser used with a Versa-Spray or Versa-Spray II control unit. To install the components, follow the instructions included with the kit.

  • Page 51: Nozzle Extension Parts And Service Kits

    S HOLDER, resistor, Versa-Spray II 169656 S RESISTOR, nozzle extension, Versa-Spray II 182255 S KIT, spider, with O-ring, Versa-Spray II - - - - - - S S SPIDER, air inlet, Versa-Spray II 940093 S S O-RING, silicone, 0.219 x 0.344 x 0.063 in.

  • Page 52: In-Line Ball Mount Kit

    8-10 Options In-Line Ball Mount Kit This kit can be used with a Versa-Spray or Versa-Spray II automatic spray gun. Installation instructions are included with each kit. See Figure 8-11. Item Part Description Quantity Note — 183539 KIT, Versa-Spray II in-line ball mount —...

  • Page 53: In-Line Ball Mount And Ion Collector Kit

    8-11 Options In-Line Ball Mount and Ion Collector Kit This kit can be used with a Versa-Spray or Versa-Spray II automatic spray gun. Installation and adjustment instructions are included with each kit. See Figure 8-12. Item Part Description Quantity Note —...

  • Page 54: Ion Collector Retrofit Kits

    S SCREW, set, cup, M5 x 5, black 189488 S BRACKET, Shur-Lok, ion collector 982628 SCREW, socket, M5 x 10, stainless steel NOTE A: Optional, replaces item 2. NS: Not Shown 1400435A Figure 8-13 Shur-Lok Mount Ion Collector Kit Part 107016-02 E 2016 Nordson Corporation...

  • Page 55: In-Line Ball Mount Ion Collector Kit

    S PLATE, ball mount, ion collector 129592 KNOB, clamping, M6 x 12 982030 SCREW, socket, M6 x 20, black NOTE A: Optional, replaces item 3. B: Optional, replaces item 2. 1400436A Figure 8-14 In-Line Ball Mount Ion Collector Kit Part 107016-02 E 2016 Nordson Corporation...
  • Page 56 8-14 Options Part 107016-02 E 2016 Nordson Corporation...
  • Page 57 II Guns Description A wide variety of nozzles are available for Versa-Spray and Versa-Spray II powder spray guns. Manual and automatic guns are shipped with different types of nozzles. All nozzles listed in this instruction sheet can be used on any manual or automatic Versa-Spray or Versa-Spray II gun.
  • Page 58 Optional Nozzles for Versa-Spray and Versa-Spray II Guns Flat-Spray Nozzle Selection (contd) Nozzle Spray Pattern Powder Velocity Application Large, flat 2.5-mm High surfaces Flat Spray 3-mm Fine finish on Medium-high Flat Spray flat surfaces 4-mm Flat Spray Medium-low Touch up...
  • Page 59 Optional Nozzles for Versa-Spray and Versa-Spray II Guns Conical Nozzle and Deflector Selection Powder Deflector Size Used with This Nozzle Spray Pattern Application Velocity 14 mm 32 mm with pattern Manual High adjuster touch-up 16 mm 32 mm with pattern...
  • Page 60 NOTE: Versa-Spray II guns with air do not use a nozzle wear sleeve. Disregard steps 2 and 3 if you have a Versa-Spray II gun with an electrode-cleaning air extension (10).
  • Page 61 These nozzle kits can be used on any Versa-Spray or Versa-Spray II manual or automatic gun. If you have a Versa-Spray II gun with an electrode-cleaning air extension, you do not need to order a nozzle kit that includes a wear sleeve (7) with O-ring (8).
  • Page 62 Optional Nozzles for Versa-Spray and Versa-Spray II Guns Conical Nozzles and Deflectors 32-mm Conical Nozzle and Deflectors See Figure 3. Item Part Description Quantity Note — 145559 SERVICE KIT, nozzle, 32 mm 133734 S 26-mm DEFLECTOR, with O-ring, Tivar 940084 S S O-RING, silicone, 0.188 x 0.312 x 0.063 in.
  • Page 63 Optional Nozzles for Versa-Spray and Versa-Spray II Guns 45-mm Conical Nozzle and Deflector See Figure 4. Item Part Description Quantity Note — 144760 SERVICE KIT, nozzle, 45 mm 249233 S 38-mm DEFLECTOR, with O-ring, Tivar 940084 S S O-RING, silicone, 0.188 x 0.312 x 0.063 in.
  • Page 64 Optional Nozzles for Versa-Spray and Versa-Spray II Guns Issued 3/03 Original copyright date 2003. Cross-Cut, Nordson, the Nordson logo, and Versa-Spray are registered trademarks of Nordson Corporation. Tivar is a registered trademark of Poly-Hi Corporation. Part 1037936A E 2003 Nordson Corporation...

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