Electrostatic powder spray gun nozzles · Flat, cross-cut, castle and conical nozzles with 16–38 mm deflectors, the charging electrode and rinsing air, wear checks and impact fusion, and fit to the gun model
An electrostatic spray gun nozzle is the replaceable outlet at the front of a corona powder or liquid electrostatic gun that shapes the powder-air or paint stream into a flat, cross-cut or conical pattern around the charging electrode, sometimes with a deflector and wear sleeve. Ask three things first: which gun model and electrode arrangement it must fit, which pattern suits the parts being coated, and what material and wear life it needs for the powder and air pressures used.
Nozzles, deflectors and wear sleeves for electrostatic powder and liquid spray guns. Complete electrostatic spray guns (see electrostatic spray gun), industrial spray nozzles for liquids (see spray nozzle), hot-melt adhesive nozzles and tungsten-carbide abrasive or jet nozzles are outside this page.
01
Nordson's Versa-Spray cable-fed automatic electrostatic powder spray gun manual (Manual 31-13, 1994) describes a corona-type gun in which powder sprayed from the nozzle passes through an electrostatic corona from the resistor electrode and picks up a charge. Standard versions use a 4 mm flat spray nozzle; options include 2.5, 3 and 6 mm flat spray nozzles, 60° and 90° cross-cut nozzles, a castle nozzle, 32 and 45 mm conical nozzles with deflectors offered in various sizes, and 150 and 300 mm lance extensions. [1]
It sets the high voltage to 100 kV at start-up, with starting pump air pressures of 30 psi (2.1 bar) atomizing and 20 psi (1.4 bar) flow rate, and says pressures will vary with film build, line speed and part configuration. [1]
Nordson's later Encore manual powder spray system manual (Part 1102729_03, issued 10/11 and marked Previous Generation) ships the gun with a 4 mm flat spray nozzle and with a conical nozzle and 26 mm deflector. Optional parts are 2.5, 3 and 6 mm flat spray nozzles, 16, 19 and 38 mm deflectors, 60 and 90 degree cross-cut nozzles, a 2.5 mm castle nozzle and 150 and 300 mm lance extensions. An optional pattern adjuster kit has an integral conical nozzle and takes the 16, 19 or 26 mm deflector, ordered separately; the 38 mm deflector cannot be used with that kit. [2]
Gema's OptiSelect Pro GM04 manual gun manual (Rev. 03 10/25) ships the gun with two complete flat jet nozzles, NF40 and NF20, each including the electrode holder. Its wearing-parts lists name flat jet nozzles NF20, NF21, NF22, NF24, NF27 and NF40 (NF24 and NF40 variants marked not suitable for angled nozzles), the round jet nozzle NS04 with Ø 16, 24 and 32 mm deflectors, and NF25, NF26 and NS09 nozzles for 150 and 300 mm gun extensions. [4]
Gema describes the flat jet nozzle as a vented nozzle that sprays and charges the powder through a central electrode, and the round jet nozzle as one whose deflector gives the emerging powder stream a cloud formation. [4]
Editorial note: the manuals list the nozzle shapes but do not give pattern widths; ask the supplier for spray pattern width at your gun-to-part distance for each nozzle, and test on sample parts with recesses and edges.
Give the supplier the gun make and model, nozzle type (flat, cross-cut, conical, castle) and size, deflector size, electrode and wear-sleeve arrangement, coating type (powder or liquid), air pressures and powder flow, part shapes and line speed, material preference and quantities of nozzles, deflectors and sleeves.
02
In both makers' guns the charging electrode sits inside the nozzle assembly, so a nozzle order is also an electrode-holder order. Gema states that its GM04 gun's cascade raises a control signal of approx. 10 V to approx. 110 kV, which is fed to the electrode within the spray nozzle; the gun's nominal output is 110 kV and maximum output current 110 µA, negative polarity with positive optional. [4]
Nordson rates the Encore applicator output at 100 kV and 100 µA. Its fixed Select Charge modes are 100 kV and 15 µA for re-coat, 50 kV and 50 µA for metallics, and 100 kV and 60 µA for deep recesses, and its factory presets spray 150 g/min (20 lb/hr) or 300 g/min (40 lb/hr) at 100 kV. [2]
Rinsing air keeps powder off the electrode. Gema uses electrode rinsing air inside the nozzle to stop powder sintering on the electrode, and rinses the deflector's baffle plate because powder can accumulate there; the setting is adjusted on the control unit to suit the nozzle fitted (deflector plate or flat jet), with displays shown at approx. 0.1 and 0.5 Nm³/h. Nordson's electrode air wash runs automatically while the gun is triggered, and its troubleshooting table lists electrode air wash flow set too high as a cause of voids in the pattern. [4] [2]
Fit is mechanical as well as electrical. The Encore nozzle is keyed to the electrode assembly and held by a nozzle nut screwed on finger-tight. Gema warns that a threaded sleeve not tightened well leaves the nozzle loosely mounted and risks a high-voltage discharge that can damage the gun. [2] [4]
Nordson's Encore porcelain enamel gun manual (Part 1604193-08) ships that gun with a ceramic conical nozzle and says the electrode holder for conical nozzles is not interchangeable with the flat and corner nozzle electrode holder; changing to an optional 4 or 6 mm flat or corner spray nozzle requires the nozzle, a new nozzle nut and the flat spray electrode holder kit, with a wear sleeve over the flat electrode holder. [3]
03
The manual lists a worn deflector or nozzle, or impact fusion, as a cause of uneven patterns and inadequate powder flow, and a worn nozzle or deflector as a cause of voids in the pattern; it advises cleaning and inspecting them, replacing worn parts, and reducing air pressure if parts wear quickly or impact fusion recurs. [1]
For conical nozzles it requires a conical wear sleeve over the electrode and resistor assembly, warns not to use the conical nozzle without the sleeve, and cautions that the electrode tip is sharp and the deflector must be installed by its edges. It instructs shutting off power and grounding the electrode before removing the gun from its mounting bar. [1]
The Encore manual repeats the pattern: a worn nozzle, deflector or electrode assembly affects the pattern, a worn nozzle or deflector causes voids, and if excessive wear or impact fusion is a problem the flow rate and atomizing air flow should be reduced. The porcelain enamel manual adds that the higher the powder velocity, the lower the transfer efficiency, and that high powder flow rates can result in faster wear of the powder contact parts. [2] [3]
Gema sets a schedule: clean the nozzle inside and outside with compressed air daily or after every shift, never immerse the parts in solvents, remove sintered powder weekly, and check the nozzle for wear monthly. A flat jet nozzle is to be replaced when the spray pattern is no longer a regular oval, when deeper grooves are in the nozzle slot or the wall thickness is no longer recognizable, or when the wedge of the electrode holder is worn; on deflector nozzles a worn wedge means replacing the electrode holder. [4]
Nordson's cleaning note warns not to immerse plastic parts in alcohol and not to get alcohol on the O-rings, because it will cause them to swell. [2]
Editorial calculation: lowering the flow-rate air from 20 psi to 15 psi is a 25% reduction in that pressure; make such changes in steps and check film build, since the manuals link higher air pressure and powder flow to faster nozzle wear and impact fusion. [1]
04
The companies in the manufacturer list below show this product on their own websites. Confirm the legal seller, factory and scope for your order.
05
This is a functional reference built from the sources cited; it is not one maker's design.
| Part | Role | Fix in the order |
|---|---|---|
| Nozzle | Shapes the spray: flat, cross-cut, castle, conical or round jet. [2] [4] | Type, size and gun model. |
| Deflector | Gives conical or round jet patterns a cloud; 16–38 mm in Encore, Ø 16–32 mm in Gema lists. [2] [4] | Diameter. |
| Wear sleeve | Protects electrode and resistor. [1] | Fit to nozzle type. |
| Electrode and holder | Charges the powder; holder style differs for conical and flat nozzles. [4] [3] | Holder kit to match nozzle. |
| Nozzle nut or threaded sleeve | Holds the nozzle; a loose fit risks high-voltage discharge. [4] [2] | Thread and fit. |
| O-rings | Seal nozzle to gun. [1] | Material. |
| Pattern adjuster sleeve | Adjusts conical pattern; Encore kit takes 16, 19 or 26 mm deflectors. [2] | Fit. |
| Ceramic nozzle and spider | Used in the Encore porcelain enamel gun. [3] | Material. |
06
An electrostatic spray gun nozzle quotation needs values for your gun and parts. The table explains each field, gives published values where a reviewed source states them, and says what to obtain from the supplier.
| Field | What it means and published values | Ask the supplier for |
|---|---|---|
| Flow Rate (L/min) | Powder output set by air: Gema default 60% powder and 4 Nm³/h total air; Encore presets 150 or 300 g/min. [4] [2] | Recommended range for the nozzle. |
| Spray Angle (°) | 60° or 90° cross-cut; flat, castle and conical options. [1] [2] | Pattern width at distance. |
| Orifice Diameter (mm) | 2.5, 3, 4 or 6 mm flat; 2.5 mm castle; 32 or 45 mm conical in the 1994 manual. [1] [2] | Size and part number. |
| Operating Voltage (V DC) | Guns rated 100 kV, 100 µA (Encore) and 110 kV, 110 µA (Gema GM04). [2] [4] | Gun models the nozzle is approved for. |
| Operating Temperature (°C) | Gema GM04 gun 5 °C to +40 °C; Encore system ambient +15 to +40 °C. [4] [2] | Range. |
| Ingress Protection | Encore system dust rating IP6X; the nozzle itself carries no rating. [2] | — |
| Material | Wear and impact fusion resistance; ceramic nozzle in the porcelain enamel gun. [1] [3] | Material and wear life. |
| Weight (kg) | Spare stock. | Weight. |
07
Paste it into your enquiry below or into an email to a maker, then replace every bracket.
Gun: [make; model; corona or tribo; powder or liquid] Nozzle: [flat; cross-cut; conical; size] Accessories: [deflector; wear sleeve; electrode] Process: [air pressures; flow; kV; line speed] Parts: [shapes; recesses] Supply: [material; quantity]
This company lists this product on its own website.
Its website lists powder coating nozzles.
Product scope checked 2026-10-12
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Nordson manuals list 2.5–6 mm flat spray, 60° and 90° cross-cut, castle and conical nozzles with 16–38 mm deflectors; Gema lists NF flat jet and NS round jet nozzles with Ø 16–32 mm deflectors. Each fits its own gun. [1] [2] [4]
A worn nozzle, deflector or electrode assembly, impact fusion, blockages or low air pressures, according to Nordson's troubleshooting tables. [1] [2]
No; the manual says not to use the conical nozzle without the wear sleeve over the electrode and resistor. [1]
Gema says when the spray pattern is no longer a regular oval, the nozzle slot shows deeper grooves, or the electrode holder wedge is worn; it calls for a monthly wear check. [4]
Sources checked 2026-10-12. Nordson's and Gema's manuals describe their own guns and are used here to show what nozzle options, charge settings and service steps cover; the Versa-Spray manual dates from 1994 and the Encore manual from 2011, while the Gema manual is Rev. 03 10/25. Fit and values for your gun must come from the gun maker's current parts list.
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