- ABC's of Spray Finishing 1-239 [ English ]
1-239-E-R2
Equipment & Techniques For Spray Finishing
ABCs of
Spray Finishing
www.binks.com1-239-E-R2 (02/2025)
ENADDITIONAL RESOURCES
For additional training and troubleshooting information, please visit us online at:
https://binks.com/troubleshooting/
Or use this QR code with your mobile device:
CUSTOMER/TECHNICAL SUPPORT
For additional copies of this guide, please visit us online at:
https://binks.com/support/customer-technical-support/
Or use this QR code with your mobile device:
TROUBLESHOOTING
Obey local or municipal regulations for product recycling and disposal.
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EN 02. TABLE OF CONTENTS
ABOUT THIS MANUAL
ITS PURPOSE
The purpose of this guide to make information available
from many resources on the subject of spray finishing.
It is our hope that this guide provides you with a start
toward perfecting your finishing skills.
While this guide examines the spray finishing operation
and its equipment from many viewpoints, there is still
much more to be learned to become truly proficient at
spray finishing.
The best way to become proficient at spray finishing is to
just do it! Many trade technical and community colleges
offer courses in spray finishing which is a great way to
improve your skills.
Many of the tricks of the professional spray finisher
involve paints and coatings. The manufacturers of these
materials routinely publish complete books on these
subjects. These publications are available in specialty
paint stores, as well as, online and will provide you with
considerable detail. Many of these books also contain
information on techniques for surface preparation.
Another important source of information, particularly on
equipment use and selection is your local spray finishing
equipment distributor. No guide or website could ever
completely cover a specialist’s indepth knowledge of
the equipment, the techniques, the maintenance and
troubleshooting.
ITS CONTENTS
This guide has been updated several times from The
ABC’s of Spray Equipment, originally published by The
DeVilbiss Company in 1954. It focuses on equipment and
techniques for spray finishing.
This guide is divided into individual sections around the
major components of an air spray system…spray guns,
electrostatic applicators, material containers, hose, air
control equipment, respirators, air compressors, spray
booths, pumps, dead end and circulating systems and
other sources of information.
A thorough understanding of the material in this guide
plus much actual spray painting practice should enable
you to handle just about any spray painting situation.
WHO SHOULD USE THIS GUIDE
This guide is intended for all paint users with various
levels of knowledge and experience within the paint
finishing industry.
MANUAL DISCLAIMER
Although we have made an effort to make this guide as
detailed and as complete as possible, be aware that the
equipment and product systems used to illustrate points
are entirely based on Binks, DeVilbiss and Ransburg
technology. DeVilbiss, Ransburg and Binks are three of
the world’s oldest and largest manufacturer of spray paint
equipment, and have maintained this leadership since its
founding in 1888.
This manual was prepared with the most accurate
information current at the time of publishing. Binks does
not accept responsibility for errors in, or omissions from,
the information contained herein.
Please get in touch with your distributor or Binks
Customer Service for additional service information and
assistance.
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EN02. TABLE OF CONTENTS
TRAINING RELATED MANUALS & PUBLICATIONS
Document Number Description
77-5300 General Equipment Safety Guide
A28-100R-9 Binks and DeVilbiss Accessories Guide
I-2190 Binks and DeVilbiss Gun Catalog
TL-00-02-R7 Solvent Selection and Cleaning Guide For Electrostatic Equipment
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EN 02. TABLE OF CONTENTS
02 CONTENTS
03 GENERAL SAFETY 1-8
SAFETY PRECAUTIONS �������������������������������������������������������������������������������������������������������������������������������������������1
HAZARDS ��������������������������������������������������������������������������������������������������������������������������������������������������������������������2
ADDITIONAL SAFETY INFORMATION ��������������������������������������������������������������������������������������������������������������������8
04 INTRODUCTION 9-10
FINISHING EQUIPMENT �������������������������������������������������������������������������������������������������������������������������������������������9
SURFACE PREPARATION �����������������������������������������������������������������������������������������������������������������������������������������9
PAINT PREPARATION ������������������������������������������������������������������������������������������������������������������������������������������������9
SOLVENT SELECTION ����������������������������������������������������������������������������������������������������������������������������������������������9
CONTROLLED PAINT RESISTIVITY ������������������������������������������������������������������������������������������������������������������������9
SOLVENT CLASSIFICATION FOR ELECTROSTATIC USAGE............................................................................10
VISCOSITY GUIDE ���������������������������������������������������������������������������������������������������������������������������������������������������10
RESISTANCE ADJUSTMENT BY SOLVENT SELECTION �����������������������������������������������������������������������������������10
EVAPORATION RATES VS. ELECTROSTATIC EQUIPMENT USED..................................................................10
COATING MATERIAL GUIDE ����������������������������������������������������������������������������������������������������������������������������������10
05 AIR ATOMIZING SPRAY GUNS 11-24
INTRODUCTION �������������������������������������������������������������������������������������������������������������������������������������������������������11
SPRAY GUN TYPES �������������������������������������������������������������������������������������������������������������������������������������������������11
OPERATION ��������������������������������������������������������������������������������������������������������������������������������������������������������������17
MAINTENANCE ��������������������������������������������������������������������������������������������������������������������������������������������������������21
TROUBLESHOOTING ����������������������������������������������������������������������������������������������������������������������������������������������23
06 ELECTROSTATIC SPRAY PROCESSES 25-32
PRINCIPLES OF ELECTROSTATICS ���������������������������������������������������������������������������������������������������������������������25
ELECTROSTATIC ADVANTAGES ���������������������������������������������������������������������������������������������������������������������������26
COATING APPLICATION �����������������������������������������������������������������������������������������������������������������������������������������26
OPERATING ELECTROSTATICS SAFETY ������������������������������������������������������������������������������������������������������������26
ELECTROSTATIC PROCESS & EQUIPMENT �������������������������������������������������������������������������������������������������������27
ELECTROSTATIC AIR SPRAY ATOMIZATION ������������������������������������������������������������������������������������������������������27
ELECTROSTATIC HVLP SPRAY ATOMIZATION ���������������������������������������������������������������������������������������������������27
ELECTROSTATIC AIRLESS SPRAY ATOMIZATION ���������������������������������������������������������������������������������������������27
ELECTROSTATIC AIR ASSISTED AIRLESS ATOMIZATION................................................................................28
ELECTROSTATIC ELECTRICAL ATOMIZATION ���������������������������������������������������������������������������������������������������28
ELECTROSTATIC ROTARY BELL ATOMIZATION ������������������������������������������������������������������������������������������������28
ELECTROSTATIC ROTARY DISK ATOMIZATION �������������������������������������������������������������������������������������������������28
ELECTROSTATIC POWDER APPLICATION ���������������������������������������������������������������������������������������������������������28
OPERATING ELECTROSTATIC COATING SYSTEMS SAFETY: PERSONNEL GROUNDING........................29
EQUIPMENT GROUNDING �������������������������������������������������������������������������������������������������������������������������������������29
GUN GROUNDING ���������������������������������������������������������������������������������������������������������������������������������������������������31
NO. 2 APPLICATOR GROUNDING ON SITE PAINTING ��������������������������������������������������������������������������������������31
07 MATERIAL CONTAINERS 33-35
INTRODUCTION �������������������������������������������������������������������������������������������������������������������������������������������������������33
08 HOSE AND CONNECTIONS 36-38
INTRODUCTION �������������������������������������������������������������������������������������������������������������������������������������������������������36
09 AIR CONTROL EQUIPMENT 39-40
INTRODUCTION �������������������������������������������������������������������������������������������������������������������������������������������������������39
10 RESPIRATORS 41-42
INTRODUCTION �������������������������������������������������������������������������������������������������������������������������������������������������������41
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EN02. TABLE OF CONTENTS
11 AIR COMPRESSORS 43-44
INTRODUCTION �������������������������������������������������������������������������������������������������������������������������������������������������������43
12 SPRAY BOOTHS 45-47
INTRODUCTION �������������������������������������������������������������������������������������������������������������������������������������������������������45
13 DIAPHRAGM PUMPS 48-50
INTRODUCTION �������������������������������������������������������������������������������������������������������������������������������������������������������48
TROUBLESHOOTING ����������������������������������������������������������������������������������������������������������������������������������������������49
14 HIGH PRESSURE SPRAYING: AIRLESS & AIR ASSISTED AIRLESS 51-52
INTRODUCTION �������������������������������������������������������������������������������������������������������������������������������������������������������51
SAFETY ���������������������������������������������������������������������������������������������������������������������������������������������������������������������51
AIRLESS AND AIR ASSISTED AIRLESS GUNS ����������������������������������������������������������������������������������������������������52
15 TWO BALL PISTON PUMPS AND DEAD END SYSTEMS 53-56
INTRODUCTION �������������������������������������������������������������������������������������������������������������������������������������������������������53
DEAD END SYSTEMS ����������������������������������������������������������������������������������������������������������������������������������������������54
SYSTEM LAYOUT �����������������������������������������������������������������������������������������������������������������������������������������������������55
TROUBLESHOOTING ����������������������������������������������������������������������������������������������������������������������������������������������56
16 FOUR BALL PISTON PUMPS AND CIRCULATING SYSTEMS 57-60
INTRODUCTION �������������������������������������������������������������������������������������������������������������������������������������������������������57
CIRCULATING SYSTEMS ���������������������������������������������������������������������������������������������������������������������������������������58
SYSTEM LAYOUT �����������������������������������������������������������������������������������������������������������������������������������������������������59
TROUBLESHOOTING ����������������������������������������������������������������������������������������������������������������������������������������������60
17 APPENDIX 61-64
PAINT AND SOLVENT SPECIFICATIONS ��������������������������������������������������������������������������������������������������������������61
VISCOSITY CONVERSION CHART �����������������������������������������������������������������������������������������������������������������������62
VOLUMETRIC CONTENT OF HOSE OR TUBE (ENGLISH UNITS).....................................................................64
VOLUMETRIC CONTENT OF HOSE OR TUBE (METRIC UNITS).......................................................................64
18 MANUAL REVISIONS 65
19 CONTACT INFORMATION 67
EN 03. SAFETY
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SAFETY
SAFETY PRECAUTIONS
Before the operation, maintenance, or servicing of this
Binks system; fully read and understand all technical
and safety literature for your product. This manual
contains information that is important for you to know and
understand.
This information relates to USER SAFETY and the
PREVENTION OF EQUIPMENT PROBLEMS.
To help you understand this information, we use
recognizable ANSI Z535 and ISO warning boxes and
symbols throughout this manual. Please obey these
safety sections.
WARNING
WARNING!: Indicates a hazardous situation that, if not
avoided, could result in death or severe injury.
CAUTION
Caution!: Indicates a hazardous situation that, if not
avoided, could result in minor or moderate injury, or
equipment damage.
NOTICE
Notice: Indicates information considered important but
not hazard related.
DANGER
DANGER!: Indicates a hazardous situation that, if not
avoided, will result in death or severe injury.
SAFETY
Safety: Indicates a type of safety instruction, or a
separate panel on a safety placard, where specific
safety-related instructions or procedures are described.
Careful study and continued use of this manual will
provide a better understanding of the equipment functions
and procedures.
This understanding will result in improved operation,
efficiency, and longer, trouble-free service with faster and
easier troubleshooting. If you need the necessary safety
literature for your specific system, contact your local
Binks representative or Binks directly.
WARNING
The hazards shown on the pages that follow can occur
during the normal use of this Binks equipment, but
not all listed hazards will be applicable to your product
model or equipment.
Repairs may only be performed by personnel
authorized by Binks.
WARNING
The user MUST read and be familiar with the Safety
Section in this manual and the safety literature therein
identified.
Only trained personnel can operate this equipment.
All personnel who operate, clean, or maintain this
equipment MUST fully read and understand this
manual! To operate and service the equipment, follow all
WARNINGS and safety requirements.
The user must be aware of and adhere to ALL local
building and fire codes and ordinances, as well as NFPA
33 AND EN 16985 SAFETY STANDARDS, LATEST
EDITION, or applicable country safety standards, before
the installation, operation, or servicing of this equipment.
NOTICE
This manual lists standard specifications and service
procedures. Differences can occur between this
literature and your equipment.
Differences in local or municipal codes, manufacturer
or plant requirements, material delivery requirements,
and more can make variations unpreventable. To
find these differences, compare this manual to your
system installation drawings and other applicable Binks
equipment manuals.
EN03. SAFETY
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AREAS
Indicate possible
hazard occurrences.
HAZARDS
Indicate possible hazards.
SAFEGUARDS
Prevention of possible hazards.
Spray Areas Fire Hazards
Improper or unsatisfactory
operation and maintenance
procedures will cause a fire
hazard.
If the safety interlocks are
disabled during operation,
protection against accidental
arcing is shut off and can cause
a fire or explosion.
Frequent Power Supply or
Controller shutdown identifies a
problem in the system. For this
occurrence, a correction will be
necessary
Fire extinguishing equipment must be present in the
spray area. Periodically run a test to make sure the
equipment stays usable.
Keep spray areas clean to prevent the build-up of
combustible residues.
Do not smoke in the spray area.
The high voltage supplied to the atomizer must be
turned off before the equipment is cleaned, flushed
or maintained.
Spray booth ventilation must be kept at the rates as
set by NFPA-33, OSHA, country, local, and municipal
codes.
If flammable or combustible solvents are used to
clean the equipment, ventilate the area.
Prevent electrostatic arcing. Maintain spark-safe
work distance between the parts that get coated and
the gun. A span of one inch for every 10KV of the
output voltage is necessary.
Do an equipment test only in areas free of
combustible material. The test may necessitate the
high voltage to be on, but only as instructed.
Non-factory replacement parts or unauthorized
equipment modifications can cause a fire or injury.
The key switch bypass is used only during setup
operation.
Do no production work with disabled safety
interlocks.
Set up and operate the paint procedure and
equipment under NFPA-33, NEC, OSHA, local,
municipal, country, and European Health and Safety
Norms.
EN 03. SAFETY
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AREAS
Indicate possible
hazard occurrences.
HAZARDS
Indicate possible hazards.
SAFEGUARDS
Prevention of possible hazards.
Spray Areas
General Use and
Maintenance
Explosion Hazard
Improper or unsatisfactory
operation and maintenance
procedures will cause a fire or
explosion hazard.
If the safety interlocks are
disabled during operation,
protection against accidental
arcing is shut off and can cause
a fire or explosion.
Frequent Power Supply or
Controller shutdown identifies a
problem in the system. For this
occurrence, a correction will be
necessary.
Improper or unsatisfactory
operation and maintenance
procedures will cause a fire
hazard.
Personnel must be correctly
trained in the operation and
maintenance of this equipment.
Prevent electrostatic arcing. Maintain spark-safe
work distance between the parts that get coated and
the gun. A span of one inch for every 10KV of output
voltage is necessary.
Unless specifically approved for use in hazardous
locations, put all electrical equipment outside of
Class I or II, Division 1 or 2 hazardous areas in
accordance with NFPA-33, or outside of Zone 2 or
Zone 22 in accordance with EN standards.
If equipped, set the current overload sensitivity as
described in the related section of the equipment
manual. If incorrectly set, the current overload
sensitivity for protection against accidental arcing is
turned off and can cause a fire or explosion.
Frequent power supply shutdown indicates a
problem in the system, which requires correction.
Always turn off the control panel power before the
system is flushed, cleaned, or servicing the spray
system equipment. Make sure no objects are within
the spark-safe work distance before the high voltage
is turned on.
The control panel must interlock with the ventilation
system and conveyor in accordance with NFPA-33,
EN 50176.
Fire extinguishing equipment must be present in the
spray area. Periodically run a test to make sure the
equipment stays usable. Do an equipment test only
in areas free of combustible material.
Train all personnel in accordance with the
requirements of NFPA-33, EN 60079-0.
Before equipment operation, personnel must read
and understand these instructions and safety
precautions.
Obey appropriate local, municipal, state, and
national codes governing ventilation, fire protection,
operation maintenance, and housekeeping.
Reference OSHA, NFPA-33, EN Norms, and your
insurance company requirements.
EN03. SAFETY
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AREAS
Indicate possible
hazard occurrences.
HAZARDS
Indicate possible hazards.
SAFEGUARDS
Prevention of possible hazards.
Spray Area High
Voltage Equipment
Electrical Discharge
This equipment contains a
high-voltage device that can
cause an electrostatic induction
on ungrounded objects. This
electrical charge is capable of
igniting coating materials.
Insufficient ground will cause a
spark hazard. A spark can ignite
many coating materials and
cause a fire or explosion.
Operators in the spray area and the parts to be
sprayed must be sufficiently grounded.
All conductive objects inside the spray area must be
grounded.
Hold the parts that get sprayed on conveyors or
hangers that are correctly grounded. The resistance
between the parts and the earth-ground must not be
more than 1 MΩ. Refer to: NFPA-33.
Before the equipment is operated, ground all
operators. They cannot wear rubber-soled insulated
shoes. Wear ground straps on wrists or legs for
sufficient ground contact.
Operators must not wear or carry ungrounded metal
objects.
When used, operators must make complete contact
with the gun handle and electrostatic gun. Use
conductive gloves or gloves with the palm section cut
out.
Operators must wear grounded footwear.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY SAFETY CODES FOR GUIDANCE TO
CORRECTLY GROUND THE OPERATOR.
Except for objects needed for the high-voltage
process, all electrically conductive objects in the
spray area are to be grounded. Supply a grounded
conductive floor in the spray area.
Always turn off the gun voltage before the system is
flushed, cleaned, or when servicing the spray system
equipment.
Unless specifically approved for use in hazardous
locations, put all electrical equipment outside of
Class I or II, Division 1 or 2 hazardous areas in
accordance with NFPA-33, or outside of Zone 2 or
Zone 22 in accordance with EN standards.
Do not install an gun into a fluid system if the solvent
supply is ungrounded.
Do not touch an energized gun electrode.
EN 03. SAFETY
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AREAS
Indicate possible
hazard occurrences.
HAZARDS
Indicate possible hazards.
SAFEGUARDS
Prevention of possible hazards.
Spray Areas
Spray Area and
Equipment Use
Toxic Fluid or Fumes
Toxic fluids or fumes can cause
severe injury or death if splashed
in the eyes or on the skin, or if
inhaled or swallowed.
High-pressure fluid sprayed
from the gun, hose fittings, or
ruptured/damaged components
can pierce the skin.
While this injury can appear as
cut skin, this is a severe injury
that can result in the amputation
of the affected area.
Read the Safety Data Sheet (SDS) for instructions
to know and understand how to handle the specific
hazards of the fluids used, and the effects of long-
term exposure.
During the spray, clean, or servicing of equipment,
or when in the work area, keep the work area fully
ventilated.
Always wear personal protective equipment (PPE)
when in the work area or during equipment operation.
Refer to the Personal Protective Equipment warnings
in this manual.
Store hazardous fluid in approved containers and
refer to local, municipal, state, and national codes
governing the disposal of hazardous fluids.
Do not point or operate the spray gun at the body
part of a person.
Do not put your hand or fingers over the gun fluid
nozzle or fittings in the hose or Proportioner.
Do not try to stop or deflect leaks with your hand,
glove, body, or shop rag.
Do not blowback fluid, as the equipment is not an
air spray system.
Relieve pressure in the supply hoses, Proportioner,
and QuickHeat™ hose before the equipment is
inspected, cleaned, or serviced.
Use the lowest possible pressure to recirculate,
purge, or troubleshoot the equipment.
Examine the hoses, couplings, and fittings every day.
Service or immediately replace parts that leak, are
worn, or are damaged. Replace high-pressure hose
sections. They cannot be recoupled or serviced.
EN03. SAFETY
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AREAS
Indicate possible
hazard occurrences.
HAZARDS
Indicate possible hazards.
SAFEGUARDS
Prevention of possible hazards.
Equipment
and Fluids
Pressurized
Aluminum Parts
Skin and Clothing Burns
Equipment surfaces and fluids
can become very hot during
operation.
The use of certain solvents and
chemicals can cause equipment
damage and severe personal
injury.
Do not touch hot fluid or equipment during operation.
Do not let clothing touch the equipment during
operation or immediately after the equipment is
stopped.
Let the equipment fully cool before the examination
or servicing of the component.
Do not use 1,1,1-trichloroethane, methylene
chloride or other halogenated hydrocarbon solvents
or fluids that contain such solvents.
These solvents can cause a severe chemical
reaction and equipment rupture that results in
equipment and property damage, serious bodily
injury, or death.
EN 03. SAFETY
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AREAS
Indicate possible
hazard occurrences.
HAZARDS
Indicate possible hazards.
SAFEGUARDS
Prevention of possible hazards.
Spray Areas Do Not Touch
The effect of paint flow rates
and formulations on the quality
of atomization can cause the
turbines to rotate at high speeds.
Do not use a rag or gloved hand against the bell
edge to stop or slow down a bell during rotation.
Do not try to clean the bell edge during rotation.
EN03. SAFETY
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If the operation of this equipment, sensors, switches, or other ancillary equipment occurs in the presence of flammable
gases and vapors, connect this equipment through intrinsic-safe or Zener barriers. Classify them as a ‘simple apparatus’
or approve them for use in these areas.
ADDITIONAL SAFETY INFORMATION
Observe all local or municipal safety measures and wear approved protective equipment when servicing this equipment.
Clean all spilled chemicals and materials and do all work in a clean and organized environment to prevent personal
injury and equipment damage.
NOTICE
During the initial commission of the equipment and at periodic times throughout equipment life, visually examine all
fluid fittings for leaks.
Periodically, it is necessary to visually examine all pieces of this equipment for signs of noticeable degradation due to
chemicals or other conditions in the equipment’s environment.
CAUTION
Only operate the equipment after you have read this section.
DANGER
To prevent injury or electrocution while the system is under power, do not contact, disconnect, or manipulate electrical
connections or devices. The main disconnect on the right side of the controller can be locked out. Follow the proper
Lockout–Tagout (LOTO) procedures for internal controller electrical work.
Only qualified electrical personnel can perform the work if diagnosis and troubleshooting are not possible during
working conditions.
WARNING
To prevent possible chemical spillage when personnel are not on site, air and fluid supplies for the equipment must be
disabled when the equipment idles for an extended period, such as an end-of-day shutdown.
SAFETY
Obey local or municipal regulations that require installed fire suppression for equipment operation.
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EN 04. INTRODUCTION
FINISHING EQUIPMENT
This guide is about the selection, use and maintenance
of finishing equipment: spray guns, tanks, cups, hoses,
compressors, regulators, spray booths, respirators, etc.
It presumes that you are familiar with standard surface
preparation techniques that may be required before
finishing actually begins. It also presumes a basic
knowledge of the many different types of paints and
coatings available. Creating a perfect finish requires a
solid knowledge of surface preparation, finishes and
spray painting equipment. The first two are extensively
covered in many other books. The manufacturers of
paints and coatings have gone to great length to publish
information on their new and existing products. But,
even an extensive knowledge of surface preparation
techniques and paint chemistry is not enough to assure a
professional finish. The finish must be applied by a spray
gun, and all the variables of its use must be mastered.
The equipment necessary to apply the finish – the spray
gun, tank, cup, regulator, hoses, compressor, etc. – must
all be matched to the job as well as to each other. That
equipment must be used and maintained properly, with
an appreciation of how and why it works the way it does.
The moment of truth for any finish happens when the
trigger is pulled. This guide focuses on that moment.
SURFACE PREPARATION
Calibrate the surface to be finished should be well
cleaned before painting. If the paint manufacturer’s
instructions call for it, the surface should be chemically
treated. Use a blow-off gun and tack rag to remove all
dust and dirt. No amount of primer or paint will cover up a
badly prepared surface.
Plastic parts may contain static electricity from the
molding process. This static attracts particles of dust and
dirt. Eliminate them by treating with destatisizing air
using a special blow-off gun that imparts a neutral charge
to the airflow.
PAINT PREPARATION
Today’s finishes are extremely complex chemical
formulations. They include both solvent and waterborne
types. Some may require the addition of solvents to form
the proper spraying viscosity. Others may simply require
the addition of a second component at a prescribed ratio
to obtain sprayable consistency. Many of them also have
hardeners or other chemicals, added to them to insure
correct color match, gloss, hardness, drying time or other
characteristics necessary to produce a first class finish.
Make sure you are familiar with the specific finish material
data sheets accompanying each material. Do not mix
materials from various manufacturers. Read and follow
directions carefully.
All finish materials must also be supplied with Safety Data
sheets (SDS). This data provides information on proper
handling and disposal of materials. Many states require
that SDS be kept on file by the user.
The first step is knowing the type and color of paint
the project requires. With these determined, follow the
manufacturer’s instruction for preparing it exactly. If you
have any doubts about how to proceed, don’t guess!
Contact your paint supplier for help. Improperly prepared
paint will never produce a good finish!
The chief characteristic that determines the sprayablility
of paint and how much film may be applied, is its viscosity
or consistency. Following the paint manufacturer’s
instructions will get you close, but for professional results,
use a viscosity cup. It is a simple but very accurate, way
to measure the thickness of paint. With the cup, you
can thin or reduce the paint to the precise consistency
required by the manufacturer.
Always prepare paint in a clean, dust-free environment.
Paint has a remarkable ability to pick up dirt. Dirty paint
will not only clog your spray gun, but it will also ruin your
paint job. Get in the habit of always pouring paint into
the cup or tank through a paint strainer. Paint is never as
clean as it looks.
SOLVENT SELECTION - ELECTROSTATIC
FINISHING
Research engineers have been working for more than
thirty years on a continuing development of electrostatic
coating processes and equipment, as well as techniques
and service to further improve the high efficiency of this
process. These techniques can be quite useful for paint
formulators by providing better wraparound; higher quality
finishes requiring less touch-up and, increasing paint film
build. This information is a guide to solvent selection to
improve electrostatic sprayability.
CONTROLLED PAINT RESISTIVITY - A
FACTOR IN FORMULATION
It has been determined that coating formulations for
electrostatic application, in addition to meeting customer
requirements for durability, drying time, gloss, etc., should
have an electrical resistance within a specified range for
best atomizing characteristics and electrical deposition.
Electrical resistivity is a characteristic which must be built
into the paint formulation. It has generally been found that
most materials can be adjusted to have suitable resistance
and still meet other requirements. We have found that
no single, simple characteristic or adjustment provides
optimum sprayability for any given coating. However,
adjustment of paint resistivity through appropriate selection
of solvents improves many paints that otherwise could not
be sprayed efficiently by the electrostatic process.
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EN04. INTRODUCTION
SOLVENT CLASSIFICATION FOR
ELECTROSTATIC USAGE
Solvents may be classified as polar or nonpolar. For
our purposes, the differences in polarity between
different solvents provides a means to adjust the total
resistivity of a paint mixture. Nonpolar solvents normally
do not improve sprayability. These solvents include
the aliphatic and aromatic hydrocarbons, chlorinated
solvents, and the turpentines. The addition of polar
solvents compatible with the basic coating material
often improves electrostatic sprayability. Polar solvents
include the ketones, alcohols, glycol ethers, esters, and
nitroparaffins.
VISCOSITY GUIDE
The initial trial paint formulation should be of high
viscosity (preferably exceeding 50 seconds on a No.
4 Ford cup) so that the reduced formula will have
satisfactorily high solids content after solvent additions.
It is usually best to adjust viscosity after resistivity,
since viscosity is a less critical factor for electrostatic
sprayability.
RESISTANCE ADJUSTMENT BY SOLVENT
SELECTION
Nonpolar solvents may be used as extenders to vary
paint viscosity or flow properties without seriously
changing the electrical resistance of the mixture. An
exception occurs with paints that are of low resistivity, for
example vinyl solutions or nitrocellulose materials. The
conductivity of these special mixtures may sometimes
be reduced to a usable factor by the addition of nonpolar
solvents.
Generally, the additions of solvent of highest polarity
will give the greatest electrical resistance reduction
to a mixture’ solvents of intermediate polarity provide
intermediate resistance reductions, etc. The adjustment
of paint resistivity to the specified optimum ranges will
usually improve its sprayability. A specific selection
should be based on the best compromise to obtain the
desired resistivity, viscosity, flow rate, evaporation rate,
cost, and other conventionally considered factors.
EVAPORATION RATES VS.
ELECTROSTATIC EQUIPMENT USED
All Ransburg No. 2 Process disk equipment requires
slower formulations than normally used for conventional
hand air guns. The larger disk diameter and higher the
speed of rotation, the slower the evaporation rates should
be made. No. 2 Process bells require paints in about the
same evaporation range as for conventional air guns,
while the No. 2 Process handguns require still faster
solvents. Because of complex interactions of solvents,
resins, and binders, it may happen that a solvent of a
certain polarity will reduce the mixture resistance more
than an equal amount of a second solvent which has
a higher polarity. As these reactions are not always
predictable, the adjustment of resistivity is necessarily a
guide trial-and-error procedure.
COATING MATERIAL GUIDE
Short oil length alkyd vehicles, with small amounts of
high polarity modifying resins like amino resins, epoxy, or
phenolic, respond well to the adjustment of resistivity by
solvent addition.
Air-dry lacquers and similar fast drying materials usually
contain so much polar solvent that their resistivity is
below the desired range. In such cases, incorporating
the maximum allowable quantity of nonpolar dilutant
(example: the substitution of esters for ketones) will
improve sprayability.
Organosols dispersed in hydrocarbons can be improved
by thinning just before use with the polar solvents of high
solvency. Reduction long before use with polar solvents
of low solvency and swellability for the dispersed resin is
also beneficial.
Most paints of high pigment volume concentration and
paints where the binder is highly nonpolar, such as
bodied linseed oil, styrenated alkyds, lacquers based
on hydrocarbon resins (like cyclized rubber or butylene
copolymers), and long oil alkyds, may be improved by
solvent adjustment, but the possible upgrading of these
materials by this method is limited. Preliminary Ransburg
research seems to indicate that the use of concentrated
additives with paints of these types offers a better
prospect for sprayability improvement.
NOTICE
Please see the Appendix section for further details
on solvent selection, evaporation rates and guide to
measuring viscosity.
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EN 05. AIR ATOMIZING SPRAY GUNS
INTRODUCTION
The spray gun is the key component in a finishing system.
It is a precision engineered and manufactured instrument.
Each type and size is specifically designed to perform a
certain, defined range of tasks.
As in most other areas of finishing work, having the
right tool for the job goes a long way toward getting
professional results.
This chapter will help you know which is the proper gun
by reviewing the Conventional Air, LVMP (Trans-Tech) and
High Volume/Low Pressure (HVLP) spray gun designs
commonly used in finishing—siphon feed, gravity feed
and pressure feed. It will also review the different types of
guns and components within each design.
A thorough understanding of the differences between
systems will allow you to select the right gun, to use it
properly to produce a high quality finish and to contribute
toward a profitable finishing operation.
SPRAY GUN TYPES
1. WHAT IS AN AIR ATOMIZING SPRAY GUNS?
Air atomizing spray guns are available in three types:
Conventional, Low Volume Medium Pressure (LVMP)
(Trans-Tech) and High Volume Low Pressure (HVLP).
Conventional air spray guns pass virtually all the input
pressure to the air cap. HVLP reduces the air pressure
internally to a much lower pressure (10 psi atomizing
pressure). LVMP is higher pressures than HVLP but
substantially lower than conventional. LVMP is nearly as
efficient as HVLP but will render a finish much closer to
conventional.
Air and material enter the spray gun through separate
passages, and are mixed at the air cap in a controlled
pattern.
2. WHAT ARE THE TYPES OF AIR SPRAY GUNS?
Air spray guns may be classified in various ways. One
way is by the location of the material container:
Figure 1 shows a gun with a cup attached below it.
Figure 3 shows a gun with a cup attached above it.
Figure 4 shows a material container some distance away
from its pressure feed gun.
The type of material feed system is also a way of
classifying guns:
Siphon Feed: draws material to the gun by siphoning as in
Figure 1.
Gravity Feed: the material travels down, carried by its own
weight and gravity as in Figure 3.
Pressure Feed: the material is fed by positive pressure as
in Figure 4.
Guns may also be classified as either external or internal
mix.
3. WHAT IS A SIPHON FEED GUN?
A spray gun design in which a stream of compressed air
creates a vacuum at the air cap, providing a siphoning
action. Atmospheric pressure on the material in the
siphon cup forces it up the pickup tube, into the gun and
out the fluid tip, where it is atomized by the air cap. The
vent holes in the cup lid must be open. This type gun
is usually limited to a one-quart, or smaller, capacity
container.
Siphon feed is easily identified by the fluid tip extending
slightly beyond the face of the air cap, as shown in Figure
2.
Siphon feed guns are suited to many color changes and
to small amounts of material, such as in touchup or lower
production operations.
4. WHAT IS A GRAVITY FEED GUN?
This design uses gravity to flow the material from the
cup, which is mounted above the gun, into the gun for
spraying. No fluid pickup tube is used, since the fluid
outlet is at the bottom of the cup.
This cup has a vent hole at the top of the cup which must
remain open. It is limited to 32 ounce capacities due to
weight and balance.
Gravity feed guns are ideal for small applications such
as spot repair, detail finishing or for finishing in a limited
space. They require less air than a siphon feed gun, and
usually have less overspray.
Figure 1: Siphon Feed Gun With Attached Cup
Figure 2: Siphon Feed Air Cap
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EN05. AIR ATOMIZING SPRAY GUNS
5. WHAT IS A PRESSURE FEED GUN?
In this design, the fluid tip is flush with the face of the
air cap (see Figure 5). The material is pressurized in
a separate cup, tank or pump. The air pressure forces
the material through the fluid tip and to the air cap for
atomization.
NOTICE
When using a gravity feed system, downsize the tip one
size from siphon. If the siphon system calls for a .070,
use a .055 or .062.
This system is normally used when large quantities of
material are to be applied, when the material is too heavy
to be siphoned from a container or when fast application
is required. Production spraying in a manufacturing plant
is a typical use of a pressure feed system
6. WHAT IS AN EXTERNAL MIX GUN?
This gun mixes and atomizes air and fluid outside the air
cap. It can be used for applying all types of materials, and
it is particularly desirable when spraying fast drying paints
such as lacquer. It is also used when a higher quality
finish is desired.
Table 1: Atomization Technology Comparison
Feed
Type
Viscosity
(#2 Zahn)
Fluid
(OZ/Minute)
Atomizing
Pressure
Production
Type
Siphon Up to 24 10-12 40-50 Low
Gravity Up to 24 10-12 30-40 Low
Pressure Up to 29 20-24 50-60 High
HVLP Up to 29 14-16 10 High
Figure 3: Gravity Feed Gun With Attached Cup
Figure 4: Typical Pressure Feed Gun With Remote Tank
Figure 5: Pressure Feed Air Cap
Figure 6: External Mix Gun
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EN 05. AIR ATOMIZING SPRAY GUNS
7. WHAT IS AN INTERNAL MIX GUN?
This gun mixes air and material inside the air cap,
before expelling them. It is usually used where low air
pressures and volumes are available, or where slow
drying materials are being sprayed. A typical example
is spraying flat wall paint, or outside house paint, with a
small compressor. Internal mix guns are rarely used for
finishing when a fast-drying material is being sprayed, or
when a high quality finish is required.
8. WHAT IS HVLP?
HVLP, or High-Volume/Low Pressure, uses a high volume
of air (typically between 15-26 CFM) delivered at low
pressure (10 psi or less at the air cap) to atomize paint
into a soft, low-velocity pattern of particles. In most cases,
less than 10 psi is needed in order to atomize.
Proper setup utilizes no more fluid and air pressure than
is needed to produce the required quality and a flow rate
that will meet production requirements. As a result, far
less material is lost in over spray, bounce back and blow
back than with conventional air spray. This is why HVLP
delivers a dramatically higher transfer efficiency (the
amount of solids applied as a percent of solids sprayed)
than spray systems using a higher atomizing pressure.
The HVLP spray gun resembles a standard spray gun in
shape and operation. Models that use high inlet pressure
(20-80 psi) and convert to low pressure internally within
the spray gun are called HVLP conversion guns. Some
HVLP models, particularly those using turbines to
generate air, bleed air continuously to minimize back
pressure against the air flow of the turbine. The air cap
design is similar to that of a standard spray gun, with a
variety of air jets directing the atomizing air into the fluid
stream, atomizing it as it leaves the tip.
HVLP is growing in popularity and new environmental
regulations are requiring it for many applications. HVLP
can be used with any low-to-medium solids materials that
can be atomized by the gun, including two-component
paints, urethanes, acrylics, epoxies, enamels, lacquers,
stains, primers,etc.
9. WHAT ARE THE PRINCIPAL PARTS OF A SPRAY
GUN?
10. WHAT HAPPENS WHEN THE TRIGGER IS
PULLED?
The trigger operates in two stages. Initial trigger
movement opens the air valve, allowing atomizing air to
flow through the gun.
Further movement of the trigger opens the fluid needle,
allowing fluid material to flow. When the trigger is
released, the fluid flow stops before the atomizing air
flow.
This lead/lag time in the trigger operation, assures a full
spray pattern when the fluid flow starts. It also assures a
full pattern until the fluid flow stops, so there is no coarse
atomization.
Figure 7: Internal Mix Gun
Figure 8: The Anatomy Of A Spray Gun
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EN05. AIR ATOMIZING SPRAY GUNS
Fewer, or smaller, orifices usually require less air, produce
smaller spray patterns and deliver less material. These
caps are designed for painting smaller objects and/or
using slower speeds.
c) Material feed system used - pressure, siphon or gravity
d) Size of fluid tip to be used (Most air caps work best
with certain fluid tip/needle combinations.)
e) Volume of air in cubic feet per minute (cfm) and
pressure in pounds per square inch (psi) available
See your specific gun service manual for the proper
selection of air cap, fluid tip and needle combinations
based upon your qualifications.
14. WHAT IS THE FUNCTION OF THE FLUID TIP
AND NEEDLE?
They restrict and direct the flow of material from the gun
into the air stream. The fluid tip forms an internal seat
for the tapered fluid needle, which reduces the flow of
material as it closes. (see Figure 11)
The amount of material that leaves the front of the gun
depends upon the viscosity of the material, the material
fluid pressure and the size of the fluid tip opening
provided when the needle is unseated from the tip. Fluid
tips are available in a variety of sizes to properly handle
materials of various types, flow rates and viscosities.
15. WHAT IS THE NOZZLE COMBINATION?
In practice, the air cap, fluid tip, needle and baffle
are selected as a unit, since they all work together to
produce the quality of the spray pattern and finish.
These four items, as a unit, are referred to as the nozzle
combination.
11. WHAT IS THE FUNCTION OF THE AIR CAP?
The air cap (see Figure 10) directs compressed air into
the fluid stream to atomize it and form the spray pattern.
(see Figure 9)
There are various styles of caps to produce different sizes
and shapes of patterns for many applications.
12. WHAT ARE THE ADVANTAGES OF THE
MULTIPLE JET CAP?
This cap design provides better atomization of more
viscous materials. It allows higher atomization pressures
to be used on more viscous materials with less danger of
split spray pattern. It provides greater uniformity in pattern
due to better equalization of air volume and pressure from
the cap. It also provides better atomization for materials
that can be sprayed with lower pressures.
13. HOW SHOULD AN AIR CAP BE SELECTED?
The following factors must be considered:
a) Type, viscosity and volume of material to be sprayed
b) Size and nature of object, or surface, to be sprayed
Figure 10: External Mix Air Cap
Figure 11: The Fluid Tip And Needle
Figure 9: Types Of Spray Patterns
NOTICE
Multiple, or larger, orifices increase ability to atomize
more material for faster painting of large objects.
Fluid Needle
Fluid Tip
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EN 05. AIR ATOMIZING SPRAY GUNS
16. WHAT ARE THE STANDARD FLUID TIP SIZES
AND FLOW RATES?
The standard sizes, corresponding fluid tip opening
dimensions and flow rates are:
17. HOW ARE FLUID TIP AND NEEDLE SIZES
IDENTIFIED?
DeVilbiss and Binks fluid tips and needles are identified
by the letters or numbers stamped on the tip and the
needle. The identification letters on these components
should match. See the appropriate DeVilbiss/Binks spray
gun guide for the proper selection of fluid tip and needle
combinations.
18. WHAT FLUID TIP AND NEEDLE COMBINATION
SIZES ARE MOST COMMON?
.042/1.1mm, .055/1.4mm and .070/1.8mm are most
commonly used. The .070/1.8mm size is used for siphon
feed, while .055/1.4mm and .062/1/6 are used for gravity
Feed. For pressure feed the most common tips are
.042/1.1mm, .055/1.4mm and .070/1.8mm.
19. HOW ARE NOZZLE COMBINATIONS
SELECTED?
Five basic considerations are involved in selecting the
nozzle combination:
• type and viscosity of material being sprayed.
• physical size of object being finished.
• desired speed/finish quality.
• gun model being used.
• available air volume (cfm) and pressure (psi) from
compressor.
The type and viscosity of the material being sprayed is
the first factor to consider.
NOTICE
Optimum fluid pressures are 8-20 psi. Pressures
greater than this generally indicate the need for a larger
fluid tip size.
NOTICE
Viscosity conversion charts are available to convert one
viscosity cup reading to another from any material or
equipment supplier.
Table 2: Conventional Air Spray
Fluid Tip I.D. Flow Rate / Material
Pressure Feed Systems
.028/.7mm Up to 12 oz/min
.0425/1.1mm Up to 20 oz/min
.055/1.4mm Up to 30 oz/min
.070/1.8mm Over 30 oz/min
.070/1.8mm Porcelain enamel
.086/2.2mm Heavy body
materials
.110/2.75mm Heavy body
materials
Siphon Feed Systems
.070/1.8mm Up to 12 oz/min
.062/1.6mm Up to 10 oz/min
Gravity Feed Systems
.055/1.4mm Up to 30 oz/min
.062/1.6mm Up to 30 oz/min
Table 3: HVLP / LVMP
Fluid Tip I.D. Flow Rate / Material
Pressure Feed Systems
.0425/1.1mm Up to 10 oz/min
.055/1.4mm Up to 14 oz/min
.070/1.8mm Up to 20 oz/min
.086/2.2mm Over 20 oz/min
Siphon Feed Systems
.086/2.2mm Up to 9 oz/min
.070/1.8mm Up to 8 oz/min
Gravity Feed Systems
.055/1.4mm Up to 12 oz/min
.062/1.6mm Up to 12 oz/min
NOTICE
The lower the viscosity of the material, the smaller the
I.D. of the fluid tip.
Table 4: Pressure Feed
Material Viscosity
(#2 Zahn) Flow Rate Tip Size
Up to 23 sec Low .0425/1.1mm
23-28 sec Medium .055/1.4mm
28-48 sec High .070/1.8mm
Over 48 sec High .086/2.2mm
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EN05. AIR ATOMIZING SPRAY GUNS
The physical size of the object to be painted must
also be considered. As a general rule, use the largest
possible spray pattern consistent with the object size.
Remember that different air caps deliver various pattern
characteristics. This can reduce both spraying time and
the number of gun passes.
The next consideration in evaluating nozzle combinations
is the speed with which the finish will be applied, and the
desired level of quality. For speed and uniform coverage,
choose a nozzle combination which produces a pattern
as wide as possible.
For finish coat work, quality is the deciding factor. Choose
a nozzle combination which produces a fine atomization
and a smaller pattern size, thereby giving greater
application control.
The model of the gun itself will limit the selection of nozzle
combination. For a siphon feed gun, there are two nozzle
types available which are suitable for finishing operations.
These nozzles have fluid tip openings of .070/1.8mm to
.086/2.2mm, and are designed to handle viscosities up to
28 seconds in a No. 2 Zahn Viscosity Cup.
For a pressure feed gun, the amount of material
discharged depends upon material viscosity, the inside
diameter of the fluid tip, the length and size of hose and
the pressure on the material container or pump.
If the fluid tip opening is too small, the paint stream will be
too high. If the fluid tip opening is too large, you will lose
control over the material discharging from the gun.
For most HVLP guns, the paint flow shouldn't exceed 16
oz. per minute. For recommended flow rates for each fluid
tip size, consult the DeVilbiss or Binks guide.
Lastly, available air supply is the last factor to consider
Pressure feed air caps consume between 7.0 and 26.0
CFM, depending on air pressure applied. If your air
supply is limited, because of an undersized compressor,
or many other air tools are in use at once, the gun will be
starved for air, producing incomplete atomization and a
poor finish.
20. WHAT ARE THE CRITERIA FOR SELECTING A
PRESSURE FEED NOZZLE?
While the fluid discharge in ounces per minute from a
siphon feed gun is relatively stable (largely because it is
determined by atmospheric pressure), the fluid discharge
from a pressure feed gun depends more upon the size of
the inside diameter of the fluid tip and the pressure on the
paint container or pump. The larger the opening, the more
fluid is discharged at a given pressure.
If the fluid tip ID is too small for the amount of material
flowing from the gun, the discharge velocity will be too
high. The air, coming from the air cap, will not be able to
atomize it properly causing a center-heavy pattern.
If the fluid tip opening is too large, material discharge
control will be lost, often resulting in a split pattern.
The fluid tip/air cap combination must be matched to each
other and to the job at hand. Spray gun catalogs include
charts to help you match them properly.
21. OF WHAT METALS ARE THE FLUID TIPS
MADE?
Tips are made of the following metals:
• 300-400 grade stainless steel for both non-corrosive
and corrosive materials
• Carboloy inserts for extremely abrasive materials
22. WHAT IS VISCOSITY?
The viscosity of a liquid is its body, or thickness, and it
is a measure of its internal resistance to flow. Viscosity
varies with the type and temperature of the liquid. Any
reference to a specific viscosity measurement must
be accompanied by a corresponding temperature
specification.
Viscosity is usually measured in poise and centipoise
(1 poise=100 centipoise). The most common
measurement used to determine viscosity in finishing
is flow rate (measured in seconds from a Zahn, Ford or
Fisher Viscosity Cup).
Viscosity conversion may be accomplished by consulting
a viscosity conversion chart.
Different viscosity cup sizes are used for different
thicknesses of materials. Each cup has a precision hole
at the bottom of the cup. Use a smaller or larger hole in
the cup depending on the thickness of the material.
Viscosity control is an extremely important and effective
method to maintain application efficiency and quality
consistency. Always measure viscosity after each batch of
material is mixed and make sure material temperature is
the same, normally 70° to 90° F.
Consult your coatings Technical Data Sheet for
temperature commendations.
23. WHAT IS THE SPREADER ADJUSTMENT
VALVE?
A valve for controlling the air to the horn holes which
regulate the spray pattern from maximum width down to a
narrow or round pattern. (See Figure 8)
24. WHAT IS THE FLUID NEEDLE ADJUSTMENT?
This adjustment controls the travel of the fluid needle,
which allows more or less material through the fluid tip.
See Figure 8.
With pressure feed systems, the fluid delivery rate should
be adjusted by varying the fluid pressure at the pressure
pot. Use the fluid adjustment knob for minor and/or
temporary flow control. This will extend the life of the fluid
needle and tip.
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EN 05. AIR ATOMIZING SPRAY GUNS
25. WHAT ARE THE COMPONENTS OF SIPHON
AND GRAVITY FEED SYSTEMS?
Typical siphon and gravity feed systems consist of; a
siphon feed or gravity feed spray gun with cup, an air
compressor (not shown), a combination filter/air regulator
and air hoses. (See Figure 12)
OPERATION
26. HOW IS SIPHON AND GRAVITY FEED
EQUIPMENT HOOKED UP FOR OPERATION?
Connect the air supply from the compressor outlet to the
filter/air regulator inlet.
Connect the air supply hose from the air regulator outlet
to the air inlet on the spray gun.
After the material has been reduced to proper
consistency, thoroughly mixed and strained, pour it into
the cup and attach the cup (siphon feed) or attach the
cup and fill with the coating (gravity feed).
27. HOW ARE SIPHON AND GRAVITY FEED
SYSTEMS INITIALLY ADJUSTED FOR SPRAYING?
1. Spray a horizontal test pattern (air cap horns
in a vertical position). Hold the trigger open
until the paint begins to run. There should be
even distribution of the paint across the full
width of the pattern. (see Figure 13). The fan
control knob is normally adjusted fully counter-
clockwise. If the distribution is not even but is
symmetrical a different fluid tip may help. If the
pattern is not symmetrical, there is a problem
with either the air cap or the fluid tip/needle that
must be corrected.
Refer to the Troubleshooting Section for
examples of faulty patterns to help diagnose
your problem.
2. Flush If the pattern produced by the above test
appears normal, rotate the air cap back to a
normal spraying position and begin spraying.
(Example - a normal pattern with a #30 air cap
will be about 9 long when the gun is held 8
from the surface).
3. With the fluid adjusting screw open to the
first thread, and the air pressure set at
approximately 30 psi, make a few test passes
with the gun on some clean paper. If there are
variations in particle size, specks and/or large
globs, the paint is not atomizing properly (see
Figure 19).
Figure 12: Siphon Feed And Gravity Feed System Components
Figure 13: Horizontal Test Pattern
Figure 14: Fluid Adjustment Screw
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EN05. AIR ATOMIZING SPRAY GUNS
4. If the paint is not atomizing properly, increase
the air pressure slightly and make another test
pass. Continue this sequence until the paint
particle size is uniform.
5. If the pattern seems starved for material,
and the fluid adjusting screw is open wide
(to the first thread), the atomization air
pressure may be too high, or the material
may be too heavy. Recheck the viscosity or
reduce the air pressure.
6. If the material is spraying too heavily
and sagging, reduce the material flow
by turning in the fluid adjusting screw
(clockwise). Remember, proper setup
utilizes no more fluid and air pressure than
is needed to produce the required quality
and a flow rate that will meet production
requirements.
28. WHAT ARE THE COMPONENTS OF A
PRESSURE FEED SYSTEM?
A pressure feed system consists of; a pressure feed
spray gun, a pressure feed tank, cup or pump, an air
filter/regulator, appropriate air and fluid hoses and an air
compressor. See Figure 16
Figure 15: Test Patterns
Figure 16: Pressure Feed System Components
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EN 05. AIR ATOMIZING SPRAY GUNS
29. HOW IS EQUIPMENT HOOKED UP FOR
PRESSURE FEED SPRAYING?
Connect the air hose from the air regulator to the air inlet
on the gun. Connect the mainline air hose to the air inlet
on the tank, cup or pump.
Connect the fluid hose from the fluid outlet on the tank to
the fluid inlet on the gun.
30. HOW IS THE PRESSURE FEED GUN ADJUSTED
FOR SPRAYING?
Open spreader adjustment valve for maximum pattern
size. (see figure 8) Open fluid adjustment screw (counter
clockwise) until maximum needle travel is achieved.
Opening beyond that point will lessen the internal spring
tension and leakage at the fluid tip may result.
31. HOW IS THE PRESSURE FEED GUN
BALANCED FOR SPRAYING?
1. Using control knob on fluid regulator, set fluid
pressure at 5 to 10 psi.
2. Using control knob on air regulator, set air
atomization pressure at 30-35 psi.
3. Spray a test pattern (fast pass) on a piece
of paper, cardboard, or wood. From that test
pattern, determine if the particle size is small
enough and uniform throughout the pattern to
achieve the required finish quality. If particle
size is too large or is giving too much texture
in the finish, turn the atomization pressure up
in 3 to 5 psi increments until particle size and
texture of finish is acceptable.
4. Spray a part with these settings. If you are
not able to keep up with the production rate
required or if the finish is starved for material,
increase the fluid pressure (or use a larger
capacity fluid tip) with the fluid regulator control
knob in 2 to 4 psi increments until required wet
coverage is accomplished.
5. Remember, as you turn up the fluid pressure
the particle size will increase. Once the
coverage required is obtained, it will be
necessary to re-adjust the atomization pressure
in 3 to 5 psi increments as explained in step
3 to insure required particle size and finish
texture is achieved.
6. If using HVLP, using an Air Cap Test Kit, verify
that the air cap pressure in not above 10 psi if
required by a regulatory agency.
After establishing the operating pressures required
for production and finish quality, develop a Pressure
Standardization program for your finish room to follow.
32. WHAT IS A PRESSURE STANDARDIZATION
PROGRAM?
After establishing air and fluid pressures that meet
required quality and production, record the data to be
used for that application for future reference. (see figure
18)
33. HOW SHOULD THE SPRAY GUN BE HELD?
It should be held so the pattern is perpendicular to the
surface at all times. Keep the gun tip 8-10 inches (air
spray guns) or 6-8 inches (HVLP guns) from the surface
being sprayed.
CAUTION
Do not exceed the container's maximum working
pressure.
Figure 17: Air Cap Test Kit
Figure 18: Pressure Standardization Chart
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EN05. AIR ATOMIZING SPRAY GUNS
35. WHAT HAPPENS WHEN THE GUN IS ARCED?
Arcing the stroke results in uneven application and
excessive overspray at each end of the stroke. When the
tip is arced at an angle 45 degrees from the surface (see
figure 19), approximately 65% of the sprayed material is
lost.
34. WHAT IS THE PROPER TECHNIQUE FOR
SPRAY GUN STROKE AND TRIGGERING?
The stroke is made with a free arm motion, keeping the
gun at a right angle to the surface at all points of the
stroke. Triggering should begin just before the edge of
the surface to be sprayed is in line with the gun nozzle.
The trigger should be held fully depressed, and the gun
moved in one continuous motion, until the other edge
of the object is reached. The trigger is then released,
shutting off the fluid flow, but the motion is continued for a
few inches until it is reversed for the return stroke.
When the edge of the sprayed object is reached on the
return stroke, the trigger is again fully depressed and
the motion continued across the object. Lap each stroke
50% over the preceding one. Less than 50% overlap will
result in streaks on the finished surface. Move the gun
at a constant speed while the trigger is pulled, since the
material flows at a constant rate.
Another technique of triggering is referred to as
feathering. Feathering allows the operator to limit fluid
flow by applying only partial trigger travel.
Figure 19: Spray Techniques
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EN 05. AIR ATOMIZING SPRAY GUNS
38. HOW SHOULD GUNS BE CLEANED?
A siphon or pressure feed gun with attached cup should
be cleaned as follows:
Turn off the air to the gun, loosen the cup cover and
remove the fluid tube from the paint. Holding the tube
over the cup, pull the trigger to allow the paint to drain
back into the cup.
Empty the cup and wash it with clean solvent and a clean
cloth. Fill it halfway with clean solvent and spray it through
the gun to flush out the fluid passages by directing stream
into an approved, closed container.
Then, remove the air cap, clean it as previously explained
and replace it on the gun. Wipe off the gun with a solvent
soaked rag, or if necessary, brush the air cap and gun
with a fiber brush using clean-up liquid or thinner.
To clean a pressure feed gun with remote cup or tank,
turn off air supply to cup or tank. Release material
pressure from the system by opening relief valve.
Material in hoses may be blown back. Lid must be loose
and all air pressure off. Keep gun higher than container,
loosen air cap and trigger gun until atomizing air forces all
material back into the pressure vessel.
A gun cleaner may be used for either type of gun. This is
an enclosed box-like structure (vented) with an array of
cleaning nozzles inside.
Guns and cups are placed over the nozzles, the lid is
closed, the valve is energized, and the pneumatically
controlled solvent sprays through the nozzles to clean the
equipment.
36. WHAT IS THE PROPER SPRAYING SEQUENCE
AND TECHNIQUE FOR FINISHING APPLICATIONS?
Difficult areas, such as corners and edges, should be
sprayed first. Aim directly at the area so that half of
the spray covers each side of the edge or corner. Hold
the gun an inch or two closer than normal, or screw
the spreader adjustment control in a few turns. Needle
travel should be only partial by utilizing the feathering
technique. Either technique will reduce the pattern size.
If the gun is just held closer, the stroke will have to be
faster to compensate for a normal amount of material
being applied to smaller areas. When spraying a curved
surface, keep the gun at a right angle to that surface at
all times. Follow the curve. While not always physically
possible, this is the ideal technique to produce a better,
more uniform, finish.
After the edges, flanges and corners have been sprayed,
the flat, or nearly flat, surfaces should be sprayed
Remember to overlap the previously sprayed areas
by 50% to avoid streaking. When painting very narrow
surfaces, you can switch to a smaller gun, or cap with a
smaller spray pattern, to avoid readjusting the full size
gun. The smaller guns are usually easier to handle in
restricted areas. A full size gun could be used, however,
by reducing the air pressure and fluid delivery and
triggering properly.
MAINTENANCE
37. HOW SHOULD THE AIR CAP BE CLEANED?
Remove the air cap from the gun and immerse it in clean
solvent. Blow it dry with compressed air. If the small
holes become clogged, soak the cap in clean solvent. If
reaming the holes is necessary, use a toothpick, a broom
straw, or some other soft implement. (see figure 20
Cleaning holes with a wire, a nail or a similar hard object
could permanently damage the cap by enlarging the jets,
resulting in a defective spray pattern.
SAFETY
All containers used to transfer flammable materials
should be grounded. Be sure to comply with local
codes regarding solvent disposal.
SAFETY
The solvent is contained, and must be disposed of
properly.
Figure 20: Cleaning The Air Cap
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EN05. AIR ATOMIZING SPRAY GUNS
NOTICE
Where local codes prohibit the use of a hose cleaner,
manually backflush the hose into the cup or tank with
solvent and dry with compressed air.
Clean the container and add clean solvent. Atomization
air should be turned off during this procedure. Pressurize
the system and run the solvent through until clean.
Clean the air cap, fluid tip and tank. Reassemble for
future use.
39. WHAT PARTS OF THE GUN REQUIRE
LUBRICATION?
The A fluid needle packing, the B air valve packing and
the C trigger bearing screw require daily lubrication with a
non-silicone gun lube.
The D fluid needle spring should be coated lightly with
petroleum jelly or a non-silicone grease (ie. Lithium).
The fluid needle spring (E) should be lightly coated with
petroleum jelly.
Thoroughly clean the air cap and baffle threads (F), and
lubricate with spray gun lube daily.
Lubricate each of these points after every cleaning in a
gun washer!
NOTICE
Be sure to comply with local codes regarding solvent
dispersion and disposal.
NOTICE
Some states codes require the use of a gun cleaner,
and it is unlawful to discharge solvent into the
atmosphere.
After cleaning a spray gun in a gun cleaner, be sure to
lubricate as indicated in Figure 22.
Use a hose cleaner to clean internal passages of spray
guns and fluid hose. This device incorporates a highly
efficient fluid header, which meters a precise solvent/air
mixture. The cleaner operates with compressed air and
sends a finely atomized blast of solvent through the fluid
passages of the hose, the spray gun, etc. This simple,
easy to use cleaner speeds up equipment cleaning and
saves solvent. Savings may be as much as 80%. It also
reduces VOC emissions.
SAFETY
Be sure that both the hose cleaner and gun are properly
grounded.
Figure 21: Using A Hose Cleaner
Figure 22: Lubrication Points
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EN 05. AIR ATOMIZING SPRAY GUNS
TROUBLESHOOTING
Problem Cause Correction
Fluid Leaking From Packing Nut
Packing nut loose Tighten, do not bind needle
Packing worn or dry Replace or lubricate
Air Leaking From Front of Gun
Sticking air valve stem Lubricate
Foreign matter on air valve or seat Replace or lubricate
Worn or damaged air valve or seat
Replace
Broken air valve spring
Bent valve stem
Air valve gasket damaged or missing
Fluid leaking or dripping from
front of pressure feed gun
Packing nut too tight Adjust
Fluid tip or needle worn or damaged Replace tip and needle with lapped or
matched sets
Foreign matter in tip Clean
Fluid needle spring broken
Replace
Wrong size needle or tip
Dry packing Lubricate
Jerky, fluttering spray
(Siphon and Pressure Feed)
Material level too low Refill
Container tipped too far Hold more upright
Obstruction in fluid passage Backflush with solvent
Loose or broken fluid tube or
fluid inlet nipple Tighten or replace
Loose or damaged fluid tip/seat Adjust or replace
Dry or loose fluid needle packing nut Lubricate or tighten
Jerky, fluttering spray
(Siphon Feed Only)
Material too heavy Thin or replace
Contained tipped too far Hold more upright
Air vent clogged Clear vent passage
Loose, damaged or dirty lid Tighten, replace or clean coupling nut
Dry or loose fluid needle packing Lubricate or tighten packing nut
Fluid tube resting on cup bottom Tighten or shorten
Damaged gasket behind fluid tip Replace gasket
Top or Bottom-Heavy Spray
Pattern*
Horn holes plugged Clean, ream with non-metallic
point (ie. Toothpick)
Obstruction on top or bottom of
fluid tip Clean
Cap and/or tip seat dirty
Right or Left-Heavy Spray Pattern*
Left or right side horn holes plugged Clean, ream with non-metallic
point (ie. Toothpick)
Dirt on left or right side of fluid tip Clean
* Remedies for heavy patterns on the top, bottom, right, and left are:
1. Examine the air cap or fluid tip for obstruction. Make a solid test spray pattern to do this test. Rotate the cap one-
half turn and spray another pattern.
a. If the defect is inverted, obstruction is on the air cap. Clean the air cap as previously instructed.
b. If the defect is not inverted, it is on the fluid tip. Examine the edge of the fluid tip for a fine burr. Remove any
burrs with #600 wet/dry sand paper.
2. Check for dried paint just inside the opening. Remove dried paint by washing with solvent.
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EN05. AIR ATOMIZING SPRAY GUNS
TROUBLESHOOTING (cont.)
Problem Cause Correction
Center-Heavy Spray Pattern
Fluid pressure too high for
atomization air (pressure feed)
Balance air and fluid pressure
Reduce spray pattern width
Material flow exceeds air cap’s
capacity Thin or reduce fluid flow
Spreader adjustment valve set too
low Adjust
Atomizing pressure too low Increase pressure
Material too thick Thin to proper consistency
Split Spray Pattern
Fluid adjusting knob turned in too far Back out counter clockwise to
achieve proper flow
Atomization air pressure too high Reduce at regulator
Fluid pressure too low (pressure
feed)
Increase fluid pressure
Change to a larger tip
Starved Spray Pattern
Inadequate material flow Back fluid adjusting screw out to first
thread or increase fluid pressure
Low atomization air pressure
(siphon feed)
Increase air pressure and
rebalance gun
Unable to Form Round Spray
Pattern
Fan adjustment stem not seating
properly Clean or replace
Dry Spray
Air pressure too high Lower air pressure
Material not properly reduced
(siphon feed) Reduce to proper consistency
Gun tip too far from work surface Adjust to proper distance
Gun motion too fast Slow down
Excessive Overspray
Too much atomization air pressure Reduce pressure
Gun too far from surface Use proper gun distance
Improper technique (arcing, gun
speed too fast)
Use moderate pace, parallel to work
surface
Excessive Fog
Too much, or too fast-drying thinner Remix properly
Too much atomization air pressure Reduce pressure
Will Not Spray
No pressure at gun Check air lines
Fluid pressure too low (internal mix
cap with pressure tank) Increase fluid pressure at tank
Fluid tip not open enough Open fluid adjusting screw
Fluid too heavy (siphon feed) Reduce fluid or change to pressure feed
Internal mix cap used with siphon
feed Change to external mix air cap
Pressure feed cap/tip used with
siphon feed Use suction feed cap/tip
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EN 06. ELECTROSTATIC SPRAY PROCESSES
PRINCIPLES OF ELECTROSTATICS
Electrostatic spray finishing combines the mechanical
process of atomization with the distributive effects of
electrical attraction and repulsion to achieve a highly
efficient product finishing operation.
Atomization is achieved in liquid systems by air, airless,
air-assisted, and rotary apparatus. The coating material
is brought into contact with or through the immediate
vicinity of highly charged electrodes. As this occurs, a
considerable level of electrical charge is transferred either
by direct contact or by passage through a highly ionized
zone near the gun tip (which can be used up to 100 kV),
to the particles or droplets of coating material. Since all
the particles or droplets are similarly charged and since
like charges repel one another. Pattern in an electrostatic
spray process tends to be larger and more evenly
distributed than that of a non-electrostatic process. This
increases the ease and efficiency.
When a metallic object, which is electrically neutral or
grounded is present, the electric field is established
between the charging electrodes of the gun and the
grounded object which, in this case, is the item we wish
to coat. The electrically charged particles or droplets of
coating material are attracted via the electric field toward
the grounded object in much the same way that iron filings
are attracted to a magnet. As the particles or droplets
come in contact with the grounded object, they begin to
dissipate their electrical charges through the metal of the
object.
With a typical electrostatic spray gun, a charging
electrode is located at the tip of the atomizer. The
electrode receives an electrical charge from a power
supply. The paint is atomized as it exits past the
electrode, and the paint particles become ionized (pick up
additional electrons to become negatively charged)
The degree to which electrostatic force influences the
path of paint particles depends on how big they are, how
fast they move, and other forces within the spray booth
such as gravity and air currents. Large particles sprayed
at high speeds have great momentum, reducing the
influence of the electrostatic force. A particle’s directional
force inertia can be greater than the electrostatic field.
Increased particle momentum can be advantageous when
painting a complicated surface, because the momentum
can overcome the Faraday cage effect; the tendency
for charged paint particles to deposit only around the
entrance of a cavity.
On the other hand, small paint particles sprayed
at low velocities have low momentum, allowing the
electrostatic force to take over and attract the paint onto
the workpiece. This condition is acceptable for simple
surfaces but is highly susceptible to Faraday cage
problems. An electrostatic system should balance paint
particle velocity and electrostatic voltage to optimize
coating transfer efficiency. Since the object is grounded
through its hanger and conveyor back to electrically
neutral earth, the charge does not accumulate in the
metal of the object, allowing it to continue to accept
more charges from newly arriving particles or droplets
of coating material. Since the particles or droplets do
not shed all of their charge immediately, and since like
charges repel each other, newly driving charged particles
or droplets will tend to be repelled from spots that are
already coated and attracted to the remaining areas of
bare metal. Similarly, particles and droplets that were
propelled beyond the grounded object will tend to curve
in around behind it, thus giving the wrap-around and
recess penetration effects associated with electrostatic
spray finishing.
If, however, a metallic or otherwise electrically conductive
object is in the vicinity which is NOT properly electrically
grounded, an entirely different process can occur. Initially,
because it is an electrically neutral condition, it will attract
the charged particles or droplets of coating material.
However, as more and more coating material arrives and
shares its charge with the object, the electrical charge
will build up in the object because there is no pathway to
ground, turning the object into a static electricity battery.
Eventually, and in many cases, this can mean just a few
seconds, enough electrical charge can accumulate in
the object that a spark can be generated between it and
the nearest ground surface. Or, similarly, an ungrounded
metallic object can simply retain its electrical charge for
an indefinite time until a grounded surface is brought near
enough for a spark to occur. This grounded surface can
be a swinging conveyor hook or an operator reaching
out to touch the charged object. Likewise, a spark can
occur between the electrostatic device and itself and a
grounded object if the electrodes or other high voltage
portion of the device are placed or brought too close to
ground.
Lastly, electrostatic spray finishing can also be used
on nonconductive or conductive plastics as well as
conductive wood objects.
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EN06. ELECTROSTATIC SPRAY PROCESSES
ELECTROSTATIC ADVANTAGES
The main benefit offered by an electrostatic painting
system is transfer efficiency. In certain applications
electrostatic bells can achieve a high transfer efficiency
exceeding 90% (see page 32). This high efficiency
translates into significant cost savings due to reduced
overspray.
A phenomenon of electrostatic finishing known as wrap
causes some paint particles that go past this workpiece
to be attracted to the back of the piece, further increasing
transfer efficiency.
Increased transfer efficiency also reduces VOC emissions
and lowers hazardous waste disposal costs. Spray booth
cleanup and maintenance are reduced.
COATING APPLICATION
Any material that can be atomized can accept an
electrostatic charge. Low-, medium-, and high-solids
solvent borne coatings, enamels, lacquers, and two-
component coatings can be applied electrostatically.
The various types of electrostatic systems can apply
coatings regardless of their conductivity. Waterborne
and metallic coatings can be highly conductive. Solvent-
borne coatings tend to be nonconductive. Any metallic
coatings can contain conductive metal particles. These
metallic coatings must be kept in circulation to prevent a
short circuit in the feed line. As high voltage is introduced
into the system, the metal particles can line up to form a
conductive path. System modifications may be required
because of coating conductivity to prevent the charge
from shorting to ground.
OPERATING ELECTROSTATICS SAFETY
Electrostatic finishing is safe if the equipment is
maintained properly and safety procedures are followed.
As electrical charges come in contact with ungrounded
components, the charges can be absorbed and stored
This is known as a capacitive charge build up. Eventually,
enough charge is built up so that when the ungrounded
item comes within sparking distance of a ground, and
is charge as a spark. Such a spark may have enough
energy to ignite the flammable vapors and mists that are
present in the spray area.
An ungrounded worker will not know that the capacitive
charge has been absorbed until it is too late. Workers
should never wear rubber or corksoled shoes, which
can turn them into ungrounded capacitors. Special shoe
grounding devices are available. If workers are using
hand-held guns, they should grasp them with bare hands
or with gloves with cut-outs for fingertips and palms that
allow adequate skin contact.
Proper grounding of all equipment that is not used for
the high-voltage process is essential. Grounding straps
should be attached to equipment and connected to
a known ground. A quick inspection of all equipment,
including conveyors and part hangers, can reveal
improper grounding.
Good housekeeping can pay dividends. Removing
paint build up from parts hangers can help ensure that
workpieces are grounded. Ungrounded objects, such
as tools and containers, should be removed from the
finishing area.
Faraday Cage Effect
Electrostatic
Field
Grounded
Work Piece
WARNING
All items in the work area must be grounded, including
the spray booth, conveyor, parts hangers, application
equipment (unless using conductive/waterborne
coatings), and the spray operator.
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EN 06. ELECTROSTATIC SPRAY PROCESSES
ELECTROSTATIC AIRLESS SPRAY ATOMIZATION
Electrostatic airless spray technology utilizes the principle
of fluid at high pressures (500-5,000 psi) atomizing
through a very small fluid nozzle orifice. Size and shape
of the spray pattern, along with fluid quality is controlled
by the nozzle orifice. Airless spray technology evolved
after air spray to aid in faster application rates using
higher delivery and heavier viscosities on larger parts.
ELECTROSTATIC AIR ASSISTED AIRLESS
ATOMIZATION
Electrostatic air-assisted airless spray technology
uses the airless spray principle to atomize the fluid at
reduced fluid pressure with assisted atomizing air to
aid in reducing pattern tailing and affect pattern shape.
Air-assist airless spray technology offers some of the
desirable characteristics of both airless spray and air
spray; the desirable characteristics being medium to high
delivery rates, ability to spray heavy viscosities at low
velocities, and high transfer efficiency.
ELECTROSTATIC PROCESS &
EQUIPMENT
The electrostatic application of atomized materials was
developed to enhance finish quality and improve transfer
efficiency.
Presently, there are seven types of electrostatic
processes for spray application:
• Electrostatic air spray atomization
• Electrostatic high-volume, low-pressure (HVLP)
atomization
• Electrostatic airless atomization
• Electrostatic air-assisted airless atomization
• Electrostatic electrical atomization
• Electrostatic rotary-type bell atomization
• Electrostatic rotary-type disk atomization
Regardless of the electrostatic finishing systems, each
has its advantages and limitations. What may be suitable
for one situation may not be suitable in another.
ELECTROSTATIC AIR SPRAY ATOMIZATION
Electrostatic air spray uses an air cap with small precision
openings that allows compressed air to be directed into
the paint for optimum atomization. Electrostatic air spray
is the most widely used type of atomization in the industry
today due to its control and versatility. Electrostatic air
spray provides very high transfer efficiency by utilizing
the electrostatic charge to wrap paint around edges
and capture overspray that would have been unusable
waste. Standard electrostatic air spray provides transfer
efficiencies in the 40 to 75% range depending on the type
of material and application.
ELECTROSTATIC HVLP SPRAY ATOMIZATION
Electrostatic HVLP spray utilizes the same atomization
characteristics as electrostatic air spray technology with
slight modifications. When using air HVLP, the pressure
of the compressed air at the air cap must be reduced to a
range of 0.1 to 10 psi.
Transfer efficiency is greater when using HVLP spray
to lower the particle velocity and atomize the material
thus causing less waste and blow-by of material.
Some electrostatic equipment can be easily converted
or transformed between air spray and HVLP spray
technology by simply changing four parts. HVLP spray
technology helps meet stringent EPA codes requiring
reduced VOCs and waste. Electrostatic HVLP spray
provides transfer efficiencies in the 40 to 80% range
depending on the type of material and application.
Air Spray Atomization Technology
This is where atomization takes place! Air cap and fluid
tip design are the key factors in atomization and transfer
efficiency
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EN06. ELECTROSTATIC SPRAY PROCESSES
ELECTROSTATIC ROTARY DISK ATOMIZATION
An electrostatic rotary-disk atomizer is a high-speed
rotary atomizer that uses centrifugal force along with
mechanical shearing to atomize coating material and
efficiently transfer the material from the disk edge to the
target being painted.
The disk is used in an omega shape loop conveyor to
coat the product. Disks may be mounted stationary and
tilted (up to 45°) to coat small parts of 12 in. or less, or
mounted on reciprocating arms to coat parts up to 40 ft. in
height but generally no wider than 4 ft. in width. The disk
produces transfer efficiencies in the 70 to 95% range.
ELECTROSTATIC POWDER APPLICATION
It is worth noting that using powder instead of liquid has
also recently been developed as another technology
to enhance finish quality, improve transfer efficiency
and lower VOC's. Powder application utilizes a similar
electrostatic processes versus liquid applications.
Electrostatic powder technology utilizes power from a
controller to power a cascade that generates a high
voltage charge to the electrode on the end of a gun. Once
the powder reaches the end of the gun it is introduced to
the high voltage charge.
The high voltage differential between the grounded work
piece and the electrode of the coating gun generates an
electric field, which transmits a negative charge on the
individual powder particles.
Since these particles have the same charge as the spray
gun, they are repelled, distributed in a fine cloud and
deposited evenly on the grounded work piece. Powder
that does not initially make contact with the work piece
is caught in the electrical field and wraps around to the
backside of the work piece.
Powder coating technology provides effective material
utilization, time savings, improved coating quality, less
cleaning effort and a healthy working environment.
ELECTROSTATIC ELECTRICAL ATOMIZATION
Electrostatic electrical atomization is accomplished
by using a rotary bell on the end of a gun to evenly
dispense paint to the edge of the bell. Once the coating
material reaches the edge of the bell it is introduced to
an electrical charge. The electrical charge at the sharp
edge (approximately 100 kV) causes paint of a medium
electrical resistance range (0.1 to 1 megohms) to
disperse onto the product. The pure electrical application
is a slightly slower process than an air spray or air-
assisted airless technology and requires a rotational type
spray paint technique, due to the bells spray pattern, but
is the most transfer efficient spray gun process in the
industry today. The ultrasoft forward velocity of the spray
pattern achieves transfer efficiencies of nearly 100% on
most products.
This high transfer efficiency spawned the industry of
painting and refurbishing machinery and furniture in
place.
ELECTROSTATIC ROTARY BELL ATOMIZATION
An electrostatic bell atomizer is a high-speed rotary bell
that uses centrifugal force and mechanical shearing to
atomize material and efficiently transfer material from the
bell edge to the target being painted.
The bell is used on a turbine motor where the pattern
is carefully directed by the use of compressed air,
introduced to the pattern at the edge of the bell cup. The
compressed air gives the material forward velocity to
aid in penetrating recessed areas. The bells are usually
mounted stationary, reciprocated or on robots to coat
products on straight line conveyors. The bells may also
be positioned on both sides of the conveyor. Rotary type
bell atomization provides transfer efficiencies in the 60 to
85% range.
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EN 06. ELECTROSTATIC SPRAY PROCESSES
SAFETY
The operator SHOULD NOT wear insulating gloves!
Special conductive gloves may be used and are
recommended.
If insulating (cloth or rubber) gloves are worn, both
palms MUST be cut out to allow bare skin contact with
the equipment! This allows the operator to change the
equipment from one hand to the other.
If gloves are worn for chemical safety, grounding wrist
straps may be connected from the operator’s wrist to
the gun assembly.
This may be accomplished safely by the use of
conductive soled shoes, disposable conductive boots, or
personnel grounding straps.
EQUIPMENT GROUNDING
In electrostatic coating systems, the flow of high voltage
power from the power supply to the atomizing head of the
gun is insulated from ground and isolated from all other
functions and equipment. When the voltage reaches the
atomizer, it is transferred to the coating material where,
by introducing a (normally) negative charge, it causes
the atomized fluid to seek the nearest (normally) positive
ground. In a properly constructed and operated system,
that ground will be the target object.
The directed conduction of the electric charge through its
array of wires, cables, and equipment is accompanied by
a variety of stray electrical charges passing through the air
by various means such as air ionization; charged particles
in the air and radiated energy. Such stray charges may be
attracted to any conductive material in the spray area. If
the conductive material does not provide a safe drain to
electrical ground, which will allow the charge to dissipate
as fast as it accumulates, it may store the charge.
When its electrical storage limit is reached, or when it is
breached by external circumstances (such as the approach
of a grounded object or person, or one at lower potential),
it may discharge its stored charge to the nearest ground.
If there is no safe path to ground (such as a ground wire)
it may discharge through the air as a spark. A spark may
ignite the flammable atmosphere of a spray area.
The hazard area extends from the point of origin up to
as much as a twenty foot radius. See the NFPA-33 for
definition and limitations of hazard area.
WARNING
ALL persons in an electrostatic coating area MUST be
grounded at ALL times!
CAUTION
The integrity of the system ground MUST be inspected
regularly and maintained. It is simple, but VITAL to be
sure that all objects in an electrostatic coating area are
grounded (reference NFPA-33).
SAFETY
Inspect all grounded wires daily. Look for good, firm
joints at all points of connection (paint pots, flow
regulators, booth wall, power supply, etc.). Look for
breaks in the ground wire.
Repair any defect IMMEDIATELY!
Inspect all conveyor apparatus (hooks, hangers, etc.)
daily. If there is any accumulation of dried coating
material on any of these objects, remove it before using
them!
Inspect the floor daily for excessive accumulation of
dried coating material (or other residue). If there is any,
remove it!
OPERATING ELECTROSTATIC COATING
SYSTEMS SAFELY
PERSONNEL GROUNDING
Daily inspection of grounding apparatus and conditions,
however, will help prevent hazards that are caused by
normal, daily operations.
Personnel grounding is the most difficult area of electrical
hazard control. Most people do not realize what excellent
capacitors they are. In a very short time, without proper
grounding, the human body can build enough static
charge to cause dangerous spark discharge.
Manual equipment operators will be grounded through
the equipment as long as it is being held in contact with
the bare skin. As soon as the equipment is released from
direct (skin) contact with the operator, other grounding
methods becomes necessary.
NOTICE
Safe grounding is a matter of proper equipment
maintenance, proper spray technique, and good
housekeeping
WARNING
ALL persons in an electrostatic coating area MUST be
grounded at ALL times!
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EN06. ELECTROSTATIC SPRAY PROCESSES
GUN GROUNDING
Procedures to be followed for safely conducting
electrostatic coating operations are outlined in Operating
Your Electrostatic Coating System Safely section in this
Service Manual.
Electrostatic systems depend on high voltage to atomize
coating material and deposit it on the target object.
During operation, the system is at high voltage. Personnel
must NEVER attempt any direct contact with the
equipment UNTIL the high voltage is OFF, the atomizer
has STOPPED rotating and the ground hook has been
attached to the gun or paint supply as indicated. The
ground hook cable MUST be secured to a proven, true
earth ground and readily accessible to the gun or paint
supply.
A ground hook is designed to be used with disk or bell
atomizers or with insulated fluid suppliers. In addition to
the aluminum hook, the standard assembly has 15 feet
of aircraft cable and a solderless connector for mounting.
One assembly should be conveniently located at each
station. After the high voltage is off and the atomizer has
stopped, the hook should be touched to the atomizer hub
or gun housing momentarily to dissipate any residual
charge. It should then be hooked to the gun housing.
DO NOT allow the hook or its cable to touch the working
edge of a disk or bell atomizer. This edge is critical to
good atomization and should ALWAYS be protected
from any contact that might cause even the slightest
damage. For overhead applicators it may be necessary to
suspend the cable with a spring or other elastic material
in order to prevent edge contact. Most Waterborne Fluid
Supply Enclosures include an insulated paint stand
plus a grounded chain link enclosure, and a gate that
is equipped with a limit switch, switch trip and control
box. The enclosure is also equipped with a standard
ground hook assembly to ground the paint supply when
personnel are inside of the enclosure.
Personnel entering an insulated fluid supply enclosure
MUST FIRST be sure that the system is NOT operating.
After entering the enclosure, the ground hook must be
attached to the paint supply BEFORE any personal
contact is made. The ground hook MUST be attached
during all service and above all, during the addition of
fluid to the supply container! When leaving the enclosure
remove the ground hook and close and secure the gate.
The warning light MUST be ON whenever the system is
operating.
WARNING
The high voltage MUST be OFF and GROUNDED
before any direct personal contact is made with
equipment.
• In order to provide the best ground connection
possible, always attach a ground wire to the terminal
indicated by the ground symbol and then to a proven,
true earth ground.
• Always check ground connections for integrity. Some
items, such as rotators and paint stands, may be
supported on insulators, but all components of the
system up to the insulator MUST be grounded.
• It is recommended that ground wires be made of No.
18, bare, stranded wire (minimum). Where possible,
use larger wire.
• Where items are mounted directly on structural
components such as building columns, the ground
connection MUST still be made.
• In many cases the structural component may be
painted or coated with an insulating material, and in
many cases the equipment will be painted. These
coatings are insulating. The ground connection must
be as perfect as possible.
NOTICE
It is a simple, but vital matter to be sure that ALL
conductive objects within the spray area are grounded
This will include such items as, but are not limited to:
cabinets, benches, housings, ladders, bases, containers,
stands, people, and product. ALL of which are not by
design, insulated from ground MUST be connected
directly and INDIVIDUALLY to true earth ground. Resting
on a concrete floor or being attached to a building
column may not always be sufficient ground.
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EN 06. ELECTROSTATIC SPRAY PROCESSES
6. Computer software such as tapes, disks,
diskettes, etc.,should be removed from inside
and the immediate surrounding area of any
enclosures that are to be painted.
7. Lightning or electrostatic voltage sparking
into an A.C. circuit can create spikes or
electromagnetic pulse (EMP) that can cause
unpredictable damage to electronic hardware.
8. Surge suppressors are available that may help
protect appliances from spikes of current if
the suppressor is in the A.C. line supplying the
appliance.
9. When painting any type of electrical control
panel or console it is generally not known
if all pushbuttons, switches, meters or pilot
lights are properly grounded. In view of this,
it is desirable to cover all of these items with
aluminum foil, which is grounded to the panel
or another earth ground.
10. All on-site painting companies should have
adequate liability insurance to protect them in
the event or any real or perceived damage as a
result of their operations.
NOTICE
In view of the above unknown and possible
uncontrolled conditions, Ransburg does not
recommend the electrostatic painting of computer
cabinets, consoles or painting in close proximity to
these devices.
Ground MUST be maintained during the addition of fluid
to any supply container! Whenever transferring flammable
fluid from one container to another, both containers MUST
be properly connected to a proven ground first and then
to each other. Personnel executing such a transfer must
also be grounded. An appropriate number of ground hook
assemblies are included with systems that require them.
NO. 2 HAND GUN GROUNDING ON SITE PAINTING
For over 50 years the No. 2 Process hand gun has been
the most widely used tool by on-site painting industry for
the refinishing of office furniture, office panels, lockers,
school furniture, and dozens of other items.
Quite often we are asked about the dangers and possible
damage to computers, phone systems, or electronically
keyed security systems when electrostatic painting is
done nearby.
Concerning those types of applications, the following
facts should be noted:
1. The No. 2 Process hand gun is not
electromagnetic. It is electrostatic (much like
the static from carpets or wool and synthetic
clothing), and works at an output of 100
kilovolts at 30-50 microamperes current draw
(100 microamperes maximum short circuit
current).
2. Unlike x-rays, electrostatics does not go
through objects.
3. Some computers and phone systems are now
shielded by the manufacturer against outside
static.
4. If the static shielding of the unit is unknown, the
keyboard, CPU (central processing unit) and
its cable preferably should be removed from
the immediate painting area for protection of
the device. If this is not feasible they should
be completely wrapped in aluminum foil that is
grounded to an earth ground. This will create
a Faraday cage around the computerized
device.
5. Electrical sparks of all types create an R.F.
energy (radio frequency) that may radiate
through the air and enter into electronic circuits.
The resulting damage is unpredictable.
NOTICE
Grounding of all conductive objects near an electrostatic
spray gun is of utmost importance.
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EN06. ELECTROSTATIC SPRAY PROCESSES
NOTICE
All figures are considered baseline. Actual transfer efficiency varies due to an unlimited number of variables.
Conditions may vary due to material and application.
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EN 07. MATERIAL CONTAINERS
INTRODUCTION
All spray painting systems from the smallest brush to the
most sophisticated finishing system must have containers
to hold the material being applied.
Material container types and sizes vary considerably,
depending on the kind of spraying system being used.
This chapter will discuss these containers, their particular
applications, their construction and maintenance.
1. WHAT ARE MATERIAL CONTAINERS?
Any container which serves as a material supply reservoir
for the spray gun. These containers are usually made of
metal or plastic with capacities of 1/2 pint or more.
2. WHAT ARE THE TYPES OF MATERIAL
CONTAINERS?
There are three common types of cups which attach to
the gun itself: Siphon, Gravity and Pressure.
There are also remote pressure cups and tanks, which
are located away from the gun. See Page 11 for types of
guns and systems.
3. WHAT ARE CUP CONTAINERS?
Cup containers are typically one quart or less, and are
used where relatively small quantities of material are
being sprayed.
4. HOW ARE MATERIAL FEED CUPS ATTACHED TO
LID ASSESMBLIES?
Cups are attached using a lid assembly (sometimes called
a cup attachment) that either clamps A or screws B onto
the cup container. (see Figure 1) Some lid assemblies are
detachable from the gun, while others are integral parts
and do not detach from less expensive models.
5. WHAT CAPACITY DOES A PRESSURE FEED
CUP HAVE?
A pressure feed cup can have a one or two quart
capacity. Anything larger is considered a pressure feed
tank, which may be positioned some distance from the
gun.
Figure 1: Cup Attachment Styles
Figure 2: Regulated 2 Qt. Pressure Cup
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EN07. MATERIAL CONTAINERS
6. HOW DO PRESSURE FEED TANKS WORK?
Pressure feed tanks are closed containers, ranging in
size from about two gallons to 60 gallons. They provide a
constant flow of material, under constant pressure, to the
spray gun.
The tank is pressurized with clean, regulated,
compressed air, which forces the fluid out of the tank
through the fluid hose to the gun.
The rate of fluid flow is controlled by increasing or
decreasing the air pressure in the tank.
A typical pressure feed tank consists of:
a) the shell
b) a clamp-on lid
c) the fluid tube
d) the fluid header
e) regulator
f) gauge
g) a safety relief valve
h) agitator
Pressure feed tanks are available with either top or
bottom fluid outlets, and with various accessories.
7. WHY ARE PRESSURE FEED TANKS
RECOMMENDED?
Pressure feed tanks provide a practical, economical
method of material feed to the gun over extended periods
of time.
They are mostly used in continuous production situations,
because the material flow is positive, uniform and
constant.
Tanks can be equipped with agitators (see Figure 3) that
keep the material mixed and in suspension.
8. WHEN IS AN AGITATOR USED IN A PRESSURE
FEED TANK?
When the material being used has filler or pigment that
must be kept in motion to keep its particles in proper
suspension. An agitator can be hand, air or electrically
driven.
9. WHAT IS A SINGLE REGULATED TANK?
This is a pressure feed tank with one air regulator
controlling only the pressure on the material in the tank.
An extra-sensitive regulator is available for use with lower
fluid flow and/or lower viscosity material where precise
control is needed.
Figure 3: Pressure Feed Tank
Figure 4: Single Regulated Tank
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EN 07. MATERIAL CONTAINERS
10. WHAT IS A DOUBLE REGULATED TANK?
This is a pressure feed tank equipped with two air
regulators.
One provides regulation for the air pressure on the
material in the tank (thereby controlling fluid flow). The
other controls atomization air pressure to the spray gun.
11. WHAT ARE CODE AND NON CODE PRESSURE
TANKS?
Code tanks are manufactured to rigid standards as
specified by the American Society of Mechanical
Engineers. (ASME) Each step of manufacture is closely
controlled, and welding of the shell is certified. Code
tanks are designed to withstand pressures up to 80 or
110 psi.
Non-code tanks are normally restricted to 3 gallons in
size or less. Due to the type of construction, non-code
tanks are rated at 80 psi or less.
12. WHAT MATERIALS ARE USED TO CONSTRUCT
PRESSURE FEED TANKS?
The smaller, non-code, light-duty tanks are made of plated
steel and have lower inlet pressure restrictions.
The heavy-duty, ASME-code tanks are made of galvanized
or 300 series stainless steel. They also have pressed or
stainless steel lids with forged steel clamps.
When abrasive or corrosive materials are being sprayed,
the tank shell is coated or lined with a special material, or a
container insert is used.
13. WHAT ARE CONTAINER INSERTS?
They are liners that are placed inside the tank to hold the
material, keeping it from direct contact with the tank walls.
They are made of disposable polyethylene.
Using inserts reduces tank cleaning time and makes color
changeover easier. They also allow multiple batches of
material to be mixed in advance.
You may want to consider stainless steel Inner containers
when using ceramics or corrosive materials.
Another option to consider is putting the coating container
directly into the tank if room allows. Be sure that the tank
pickup tube does not touch the bottom of the coating
container inserted into the tank.
14. WHEN WOULD YOU USE A BOTTOM OUTLET
TANK?
• When you are using more viscous materials.
• When continuous, steady pressure is required, such
as when feeding plural component proportioning
equipment.
• When you wish to use all the material in the tank and
you are not using an insert.
15. WHAT WOULD I USE IF I HAVE DIFFICULTY
ACCURATELY SETTING LOWER FLUID
PRESSURES?
An extra-sensitive regulator is available for use with lower
fluid flow and/or lower viscosity materials where precise
control is needed.
Figure 5: Double Regulated Tank
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EN08. HOSE AND CONNECTIONS
INTRODUCTION
The various types of hose used to carry compressed air
and fluid material to the spray gun are important parts of
the system.
Improperly selected or maintained hose can create a
number of problems. This chapter will review the different
kinds of hose and fittings in use, provide guidance in
selecting the proper types for the job and cover the
maintenance of hose.
1. WHAT TYPES OF HOSE ARE USED IN SPRAY
PAINTING?
There are two types:
• air hose - used to transfer compressed air from the air
source to the gun and
• fluid hose - used only in pressure feed systems to
transfer the material from its container to the spray
gun.
2. HOW IS THE HOSE CONSTRUCTED?
Binks/DeVilbiss hose is a performance designed
combination of three components; A Tube, B
Reinforcement and C Cover.
The tube is the interior flexible artery that carries air or
fluid material from one end of the hose to the other.
The reinforcement adds strength to the hose. It is
located between the tube and cover, and it can be many
combinations of materials and reinforcement design. Its
design determines pressure rating, flexibility, kink and
stretch resistance and coupling retention.
The cover is the outer skin of the hose. It protects
the reinforcement from contact with oils, moisture,
chemicals and abrasive objects. The cover protects
the reinforcement, but does not contribute to hose
performance.
3. WHAT TYPE OF TUBE IS USED IN THE FLUID
HOSE?
Since the solvents in coatings would readily attack and
destroy ordinary rubber compounds, fluid hose is lined
with special nylon solvent-resistant material that is
impervious to common solvents.
4. WHAT SIZE OF FLUID HOSE ARE
RECOMMENDED?
5. WHAT SIZES OF AIR HOSE ARE
RECOMMENDED?
The hose from the regulator to a gun or tank should be a
minimum of 5/16 ID. Tools requiring more air may need
3/8 ID hose or larger.
NOTICE
Do not use air hose for solvent-based materials.
Figure 2: Recommended Fluid Hose Sizes
Type Length Size
General
Purpose
0'-20' 1/4 ID
10'-35' 3/8 ID
35'-100' 1/2 ID
100'-200' 3/4 ID
SAFETY
Hose color coding is as follows:
Red or Tan: Air and water
Grey: Air with static ground
Black: Low pressure fluid
Tan: Conductive
Figure 3: Recommended Air Hose Sizes
Type Length Size
Air Tools 0'-10' 1/4 ID
General
Purpose
10'-20' 5/16 ID
20'-50' 3/8 ID
50'-100' 1/2 ID
HVLP
0' to 20' 5/16 ID
20' - 50' 3/8 ID
50'-100' 1/2 ID
Figure 1: Basic Hose Construction
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EN 08. HOSE AND CONNECTIONS
6. WHAT IS PRESSURE DROP?
This is the loss of air pressure due to friction (caused by
air flow) between the source of the air and the point of
use. As the air travels through the hose or pipe, it rubs
against the walls. It loses energy, pressure and volume as
it goes.
7. HOW CAN THIS PRESSURE DROP BE
DETERMINED?
At low pressure, with short lengths of hose, pressure drop
is not particularly significant. As pressure increases, and
hose is lengthened, the pressure rapidly drops and must
be adjusted.
All air hose is subject to pressure loss or drop. For
example, 1/4 pressure drop is 1 psi per foot and 5/16
is 1/2 psi per foot. This pressure loss may result in poor
atomization.
Too often, a tool is blamed for malfunctioning, when the
real cause is an inadequate supply of compressed air due
to an undersized ID hose.
8. HOW ARE HOSES MAINTAINED?
Hoses will last a long time if they are properly maintained.
Proper hose cleaning techniques are covered on page
22. The outside of both air and fluid hose should be
occasionally wiped down with solvent. At the end of every
job, they should be stored by hanging up in coils.
9. WHAT KINDS OF HOSE FITTINGS ARE
AVAILABLE?
Permanent, crimp type or reusable fittings are used to
connect hoses to air sources or to spray equipment.
10. WHAT KIND OF HOSE CONNECTIONS ARE
AVAILABLE?
Although there are many different styles, the two most
common are the threaded and the quick-disconnect
types.
Remember that elements added to any hose, such as
elbows, connectors, extra lengths of hose, etc., will cause
a pressure drop.
On HVLP systems, quick-disconnects must have
larger, ported openings to deliver proper pressure for
atomization. Because of normal pressure drop in the
devices, they are not recommended for use with HVLP.
11. WHAT IS A THREADED TYPE CONNECTION?
This is a common swivel-fitting type that is tightened with
a wrench.
NOTICE
For optimum spray gun results, the following is
recommended: up to 20 ft - 5/16 I.D. only over 20 ft -
3/8 I.D.
SAFETY
Be careful when dragging hose across the floor. It
should never be pulled around sharp objects, run over
by vehicles, kinked or otherwise abused. Hose that
ruptures in the middle of a job can ruin or delay the
work.
Figure 4: Threaded Type Connection
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EN08. HOSE AND CONNECTIONS
12. WHAT IS A QUICK DISCONNECT TYPE
CONNECTION?
This is a spring-loaded, male/female connection system
that readily attaches and detaches by hand. No tools are
required.
13. WHAT KIND OF THREADED STYLES ARE
AVAILABLE?
Pipe threads made in the United States are different from
the pipe threads made in the United Kingdom. In the
United States and Canada NPT (National Pipe Taper)
threads are primarily used in industry applications.
In the United Kingdom and a majority of the world BSPP
(British Standard Pipe Parallel) threads are primarily used
in industry applications.
The main difference is the thread angle. It is not
recommended to connect NPT and BSPP together as this
will cause leaks and damage the threads because they
are not compatible.
Additionally, there are two other popular threads you may
come across, NPS (National Pipe Straight) and BSPT
(British Standard Pipe Taper). NPS threads are straight/
parallel when compared to NPT. BSPT threads are
tapered when compared to BSPP.
Lastly, there is a high probability that you will come in
contact with different threads on components that need to
be connected together if these parts were manufactured
in different countries.
Figure 5: Quick Disconnect (QD) Type Connection
NOTICE
Care should be taken when selecting a quick,
detachable air connection. Due to design, most quick
disconnects (QD) result in significant pressure drop.
This can adversely affect spray guns with higher
consumption air caps such as HVLP.
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EN 09. AIR CONTROL EQUIPMENT
INTRODUCTION
The control of the volume, the pressure and the
cleanliness of the air entering the spray gun are of critical
importance to the performance of the system.
Following some key installation principles will help
decrease the risk of contaminants. For example, it’s
important to use the right size air compressor for your
application. An overworked air compressor can produce
a significant amount of dirt and oil. Additionally, proper
piping is very important to help prevent condensation from
forming within the line and contaminating the air supply.
This chapter examines the various types of equipment
available to perform these control functions.
1. WHAT IS AIR CONTROL EQUIPMENT?
Any piece of equipment installed between the air source
and the point of use that modifies the nature of the air
stream.
2. WHY IS AIR CONTROL EQUIPMENT
NECESSARY?
Raw air, piped directly from an air source to a spray
gun, is of little use in spray finishing. Raw air contains
small, but harmful, quantities of water, oil, dirt and other
contaminants that will alter the quality of the sprayed
finish. Raw air will likely vary in pressure and volume
during the job.
There will probably be a need for multiple compressed air
outlets to run various pieces of equipment.
Any device, installed in the air line, which performs one
or more of these functions, is considered to be air control
equipment.
3. WHAT ARE THE TYPES OF AIR CONTROL
EQUIPMENT?
Air control equipment comes in a wide variety of types,
but it basically all performs one or more of the following
functions; air filtering/cleaning, air pressure regulation/
indication and air distribution through multiple outlets.
4. HOW DOES AN AIR FILTER WORK?
It filters out water, oil, dust and dirt before they get on
your paint job. Air entering the filter is swirled to remove
moisture that collects in the baffled quiet zone.
Smaller impurities are filtered out by a filter. Accumulated
liquid is carried away through either a manual or
automatic drain.
5. WHAT IS AN AIR REGULATOR?
This is a device for reducing the main line air pressure as
it comes from the compressor. Once set, it maintains the
required air pressure with minimum fluctuations.
Regulators are used in lines already equipped with an air
filtration device.
Air regulators are available in a wide range of cfm and
psi capacities, with and without pressure gauges and in
different degrees of sensitivity and accuracy.
They have main line air inlets and regulated or non-
regulated air outlets.
Figure 1: Air Filter
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EN09. AIR CONTROL EQUIPMENT
6. HOW IS AN AIR FILTER/REGULATOR
INSTALLED?
Bolt (A) the air filter/regulator securely to the spray booth.
(see Figure 2)
This location makes it convenient to read the gauges and
operate the valves. Install the filter/ regulator at least 25
feet from the (B) compressed air source. Install the (C)
takeoff elbow on top of the (D) main air supply line.
Piping should slope back toward the compressor, and a
(E) drain leg should be installed at the end each branch, to
drain moisture from the main air line.
Use piping of sufficient I.D. for the volume of air being
passed, and the length of pipe being used.
7. HOW OFTEN SHOULD THE FILTER/REGULATOR
BE DRAINED OF ACCUMULATED MOISTURE AND
DIRT?
It depends largely on the level of system use, the type of
filtration in the air system, and the amount of humidity in
the air.
For average use, once-a-day drainage is probably
sufficient.
For heavily-used systems, or in high humidity, drainage
should occur several times daily.
Some units drain automatically when moisture reaches a
predetermined level.
8. WHAT STEPS SHOULD BE TAKEN IF MOISTURE
PASSES THROUGH THE FILTER/REGULATOR?
Since moisture in the spray gun atomization air will ruin a
paint job, it must be removed from the air supply.
When the compressed air temperature is above its dew
point temperature, oil and water vapor will not condense
out into solid particles.
Check the following:
• Drain filter, air receiver and air line of accumulated
moisture.
• Be sure the filter is located at least 25 feet from the
air source.
• Main air line should not run adjacent to steam or hot
water piping.
• Compressor air intake should not be located near
steam outlets or other moisture-producing areas.
• Outlet on the air receiver should be near the top of
the tank.
• Check for damaged cylinder head or leaking head
gasket, if the air compressor is water cooled.
• Intake air should be as cool as possible.
9. WHAT CAUSES EXCESSIVE PRESSURE DROP
ON THE MAIN LINE GAUGE OF THE FILTER/
REGULATOR?
• The compressor is too small to deliver the required air
volume and pressure for all tools in use.
• The compressor is not functioning properly.
• There is leakage in the air line or fittings.
• Valves are partially opened.
• The air line, or piping system, is too small for the
volume of air required. Refer to page 37.
Table 1: Minimum Pipe Size Recommendations
Compressor Main Air Line
HP CFM Length Size
1 1/2 - 2 6-9 Over 50' 3/4
3-5 12-20
Up to 200' 3/4
Over 200' 1
5-10 20-40
Up to 100' 3/4
100' to 200' 1
Over 200' 1 1/4
10-15 40-60
Up to 100' 1
100' to 200' 1 1/4
Over 200' 1 1/2
NOTICE
Piping should be as direct as possible. If a large
number of fittings are used, larger I.D. pipe should be
installed to help overcome excessive pressure drop.
Figure 2: Air/Filter Regulator Installation
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EN 10. RESPIRATORS
INTRODUCTION
Spray finishing creates a certain amount of overspray,
hazardous vapors and toxic fumes. This is true, even
under ideal conditions, and there is no way to avoid it
entirely.
Anyone near a spray finishing operation should use some
type of respirator, or breathing apparatus.
This chapter covers various types of equipment for this
use.
1. WHAT IS A RESPIRATOR?
A respirator is a mask that is worn over the mouth and
nose to prevent the inhalation of overspray fumes and
vapor.
2. WHY IS A RESPIRATOR NECESSARY?
For two reasons:
Concerning those types of applications, the following facts
should be noted:
1. Respiratory protection is required by OSHA/
NIOSH regulations.
2. Even if it wasn't a requirement, common sense
tells you that inhaling overspray is not healthy.
Overspray contains toxic particles of paint pigments,
harmful dust and vapor. Exposure to any of the above is
a potential health risk. Depending on design, a respirator
can remove some, or all, of these dangerous elements
from the air around a spray finishing operator.
3. WHAT TYPES OF RESPIRATORS ARE USED BY
SPRAY FINISHING OPERATORS?
There are three primary types; the air-supplied respirator,
the organic vapor respirator and the dust respirator.
4. WHAT IS AN AIR SUPPLIED RESPIRATOR?
This type is available in both mask and visor/hood styles.
Both provide the necessary respiratory protection when
using materials that are not suitable for organic vapor
respirators.
The visor/hood style provides a greater degree of
coverage to the head and neck of the operator.
Both styles require a positive supply of clean, breathable
air as defined by OSHA (Grade D).
Figure 2: Positive Pressure Mask Respirator
Figure 1: Positive Pressure Visor/Hood
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EN10. RESPIRATORS
6. WHAT IS A DUST RESPIRATOR AND WHERE IS
IT USED?
Dust respirators are sometimes used in spray finishing but,
in most applications, they are unsatisfactory. (see Figure 4)
These respirators are equipped with cartridges that remove
only solid particles from the air. They have no ability to
remove vapors.
They are effective, however, in preliminary operations such
as sanding, grinding and buffing.
5. WHAT IS AN ORGANIC VAPOR RESPIRATOR
AND WHERE IT IS USED?
This type of respirator, which covers the nose and mouth,
(see Figure 3) is equipped with a replacement cartridge
that removes the organic vapors by chemical absorption.
Some are designed with a prefilter to remove solid
particles from the air before it passes through the
chemical cartridge.
The organic vapor respirator is usually used in finishing
operations with standard materials. (not suited for paints
containing isocyanates).
NOTICE
Before using any respirator, carefully read the
manufacturer’s Safety Precautions, Warnings and
Instructions. Many respirators are not suitable for use
with isocyanates, asbestos, ammonia, pesticides, etc.
Figure 3: Organic Vapor Respirator
Figure 4: Dust Respirator
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EN 11. AIR COMPRESSORS
INTRODUCTION
All air tools, spray guns, sanders, etc., must be supplied
with air which is elevated to the higher pressures and
is delivered in sufficient volume. The air compressor
compresses air for use in this equipment and is a major
component of a spray painting system. This chapter will
examine the various types available.
Compressed air is measured on the basis of the volume
supplied per unit of time (cubic feet per minute, or cfm)
at a given pressure per square inch (psi), referred to as
delivery.
Displacement is the output of air by a compressor at zero
pressure, or free air delivery.
1. WHAT IS AN AIR COMPRESSOR?
An air compressor is a machine designed to raise the
pressure of air from normal atmospheric pressure to
some higher pressure, as measured in pounds per square
inch (psi). While normal atmospheric pressure is about
14.7 pounds per square inch, a compressor will typically
deliver air at pressures up to 175 psi.
2. WHAT TYPES OF COMPRESSORS ARE MOST
COMMON IN SPRAY FINISHING OPERATIONS?
There are two common types; the piston-type design
and the rotary screw design. Because most commercial
spray finishing operations consume large quantities of
compressed air at relatively high pressures, the piston
type compressor is the more commonly used.
3. HOW DOES A PISTON TYPE COMPRESSOR
WORK?
This design elevates air pressure through the action
of a reciprocating piston. As the piston moves down,
air is drawn in through an intake valve. As the piston
travels upward, that air is compressed. Then, the now-
compressed air is discharged through an exhaust valve
into the air tank or regulator.
Piston type compressors are available with single or
multiple cylinders in one or two-stage models, depending
on the volume and pressure required.
4. HOW DOES A ROTARY SCREW COMPRESSOR
WORK?
Rotary screw compressors utilize two intermeshing
helical rotors in a twin bore case. Air is compressed
between one convex and one concave rotor. Trapped
volume of air is decreased and the pressure is increased.
NOTICE
When selecting a compressor remember this rule
of thumb. The cubic feet per minute delivered by an
electrically powered 2 stage industrial air compressor is
4 times the motor's horse power rating. (CFM=4xHP)
Figure 1: Piston Type Air Compressor
Figure 2: Rotary Type Screw Air Compressor
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EN11. AIR COMPRESSORS
5. WHAT IS A SINGLE STAGE COMPRESSOR?
This is a piston-type compressor with one or more
cylinders, in which air is drawn from the atmosphere and
compressed to its final pressure with a single stroke. All
pistons are the same size, and they can produce up to
125 psi.
6. WHERE ARE A SINGLE STAGE COMPRESSORS
USED?
The application of this compressor is usually limited to a
maximum pressure of 100 psi. It can be used above 100
psi, but above this pressure, two stage compressors are
more efficient.
7. WHAT IS A TWO STAGE COMPRESSOR?
A compressor with two or more cylinders of unequal size
in which air is compressed in two separate steps.
The first (the largest) cylinder compresses the air to
an intermediate pressure. It then exhausts it into a
connecting tube called an intercooler.
From there, the intermediate pressurized air enters
the smaller cylinder, is compressed even more and is
delivered to a storage tank or to the main air line.
Two stage compressors can deliver air to over 175
psi and are normally found in operations requiring
compressed air of 125 psi or greater.
8. WHAT ARE THE BENEFITS OF TWO STAGE
COMPRESSORS?
Two stage compressors are usually more efficient. They
run cooler and deliver more air for the power consumed,
particularly in the over 100 psi pressure range.
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EN 12. SPRAY BOOTHS
INTRODUCTION
Containing the overspray and keeping it out of the air and
off other objects is an important consideration in a spray
finishing operation.
This chapter looks at the primary method of controlling
overspray in the spray booth. It discusses various types of
booths and details periodic maintenance.
1. WHAT IS A SPRAY BOOTH?
A compartment, room or enclosure of fireproof
construction; built to confine and exhaust overspray and
fumes from the operator and finishing system.
There are various models available, designed for
particular spray applications.
2. WHAT ARE THE BENEFITS OF A SPRAY BOOTH?
A well-designed and maintained spray booth provides
important advantages:
• It separates the spraying operation from other shop
activities, making the spraying, as well as the other
operations, cleaner and safer.
• It reduces fire and health hazards by containing the
overspray.
• It provides an area that contains residue, making it
easier to keep clean. It also keeps both the operator
and the object being sprayed cleaner.
• In a booth equipped with adequate and approved
lighting, it provides better control of the finish quality.
3. WHAT TYPES OF SPRAY BOOTHS ARE THERE?
There are two; the dry filter type and the waterwash type.
4. WHAT IS A DRY FILTER TYPE SPRAY BOOTH?
This booth draws overspray contaminated air through
replaceable filters and vents the filtered air to the outside.
It is the most common type of booth for most industrial
applications.
It is used for spraying low-volume, slower-drying
materials, and is not affected by color changes.
5. WHAT IS A WATERWASH TYPE BOOTH?
A waterwash booth (see figure 2) actually washes the
contaminated overspray air with a cascade of water, and
traps the paint solids. Fewer paint particles reach the
outside atmosphere to harm the environment.
Waterwash booths are generally used when spraying
more than 15 gallons of material a day.
SAFETY
Consult the National Fire Protection Association (NFPA)
pamphlet #33 and the O.S.H.A. requirements for
construction specifications. Figure 1: Dry Filter Type Spray Booth
Figure 2: Waterwash Type Spray Booth
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EN12. SPRAY BOOTHS
Too high a velocity wastes power and the energy required
to heat make-up air.
9. WHAT IS A MANOMETER?
It is a draft gauge which indicates when paint arrestor
filters or intake filters are overloaded.
10. WHAT DOES AN AIR REPLACEMENT UNIT DO?
The volume of air exhausted from a spray booth is often
equal to three or more complete air changes per hour.
Under such conditions, the temperature may become
irregular and uncomfortable. Excessive dust may become
a problem.
To prevent these conditions, sufficient make-up air must
be introduced to compensate for the exhausted air.
The air replacement unit automatically supplies this
makeup air - both filtered and heated - to eliminate the
problems of air deficiency.
NOTICE
Some states and local codes require a manometer
gauge on each bank of filters to comply with OSHA
regulations.
6. WHAT IS AN EXHAUST FAN?
A typical exhaust fan (see figure 4) consists of a motor,
a multiple blade fan, pulleys and belts. It removes
overspray from the spray booth area.
Contemporary exhaust fans are carefully designed to
prevent overspray from coming into contact with the drive
mechanism.
Blades are made of non-sparking metal, and they move
the maximum volume of air-per-horsepower against
resistance such as exhaust stacks, filters, etc. (See NFPA
pamphlet #33.)
7. WHAT IS AIR VELOCITY?
Air velocity in a finishing operation is the term used to
describe the speed of air moving through the empty spray
booth.
8. WHAT EFFECT HAS AIR VELOCITY ON SPRAY
BOOTH EFFICIENCY?
Air must move through the booth with sufficient velocity to
carry away overspray.
Too low a velocity causes poor, even potentially
dangerous working conditions, especially when the
material contains toxic elements. It also increases
maintenance costs.
Figure 3: Automotive Downdraft Dry Filter Type Spray Booth
Figure 4: Exhaust Fan
Figure 5: Manometer
Figure 6: Air Replacement Unit
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EN 12. SPRAY BOOTHS
11. WHAT ROUTINE MAINTENANCE DOES A DRY
TYPE SPRAY BOOTH REQUIRE?
• The continuous flow of air through the booth
eventually loads the filters with dirt and overspray.
Periodically, inspect and replace them with multistage
filters, designed for spray booth use. Single-stage
furnace filters will not do the job.
• Monitor the manometer readings daily, and know
what a normal reading should be.
• Keep the booth free of dirt and overspray. Floors and
walls should be wiped down after every job. Pick up
scrap, newspapers, rags, etc.
• Coat the inside of the booth with a strippable, spray-
on covering. When the overspray on it becomes too
thick, strip and recoat.
• Periodically check the lighting inside the booth, and
replace weak or burned out bulbs. Improper lighting
can cause the operator to apply a poor finish.
12. WHAT ROUTINE MAINTENANCE DOES A
WATERWASH TYPE BOOTH REQUIRE?
• Compounding of the water in this type unit is
essential. Employ only booth treatment chemicals in
accordance with suppliers' recommendations. The ph
of the water should be between 8 and 9.
• Maintain the water level at the proper setting per
manufacturers' specifications.
• Check the tank for paint buildup on the bottom,
check the pump strainer to keep it clean and clear,
check the air washer chamber and the nozzles in
the header pipe. If the nozzles are plugged, the
overspray will encroach on the wash baffle section,
fan and stack.
• Periodically check the float valve for proper operation.
Flood the sheet to be sure there is a uniform flow
over the entire surface.
• Keep the booth interior and exhaust stack free from.
overspray and dirt accumulation.
13. WHAT CHECKS CAN BE USED TO ASSURE
GOOD RESULTS FROM A SPRAY BOOTH?
• Keep the interior of the booth clean.
• Maintain and replace intake and exhaust filters when
necessary.
• Caulk all seams and cracks where dirt might enter.
• Maintain and clean all equipment used in the booth.
• Keep operators clothing clean and lint-free.
• Perform routine maintenance above on a scheduled
basis.
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EN13. DIAPHRAGM PUMPS
INTRODUCTION
Diaphragm pumps can serve several purposes in a spray
system. The can be used as a transfer pump to move
coatings from one container to another (ie. drum to a
pressure pot).
In many cases larger diaphragm pumps can be used in
a paint supply room to supply pressure to low pressure
spray guns either in a dead-end system or a circulating
system.
They may also be used in the spray booth to siphon
directly out of a container supplying low pressure coatings
to the spray gun. If required the coating could be returned
to the source in a circulating system.
1. HOW ARE DIAPHRAGM PUMP PRESSURES
DETERMINED?
Diaphragm pumps are normally a 1:1 ratio. The maximum
pressure would be limited by the pump design (ie. 100
psi) or by the available pressure to the pump.
2. WHAT IS MEANT BY PRIMING THE PUMP?
Before setting working fluid pressures, start an empty
pump by slowly opening the air pressure valve (or
regulator) to the air motor. When the pump no longer
cycles (full of coating), set the fluid pressure to the
working pressure.
If the air motor receives full working pressure with an
empty fluid section, the fluid section contains air and will
initially run at high speed with no lubrication. This will
increase the risk of damaging the fluid section.
3. HOW DOES A DIAPHRAGM PUMP WORK?
We will assume the pump in figure 2 is primed and the
connecting rod at its maximum leftward movement and
the pump is ready to move to the right. When fluid is
called for, both diaphragms begin to move to the right
via the rod connecting them. The four ball/seat valves
behave as follows:
• Ball Check A Remains closed due to pressure in the
right hand chamber.
• Ball Check B Opens to allow fluid in the right hand
chamber to exit the pump.
• Ball Check C Remains closed due to pressure in the
upper portion of the pump.
• Ball Check D Opens to allow fluid to be siphoned
from the material container.
When the connecting rod causes both diaphragms to
move to the left, the four ball check behave in a direction
opposite to the above.
Figure 1: Wall Mount Gemini Two Pump
Figure 2: Diaphragm Pump Section View
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EN 13. DIAPHRAGM PUMPS
HOW DO I TROUBLESHOOTING A DIAPHRAGM PUMP AIR MOTOR?
Problem Cause Correction
Freezing Air Motor
Air exhausting from the pump at
higher cycle rates tends to freeze
(stall) the motor.
Pipe exhaust away from pump.
Reduce pump cycle rate (see pump
service manual).High humidity and/or cycle rate.
Dirt, Debris, Oil and/Or Water
In Air Supply
Dirt can plug internal ports & shear
air motor o-rings.
Improper or excess lubrication can
cause air motor o-rings to swell and
stall the pump.
Water can wash out factory installed
lubricant, leading to pump failure.
Install air filtration (clean/dry air).
Check main air supply.
Install proper filtration.
Material Discharged From Air
Exhaust When Idle
Diaphragm failure, or diaphragm
plates loose.
Replace diaphragms, check for damage
and ensure diaphragm plates are tight.
Worn or damaged diaphragm.
Inspect and if need replace diaphragm.
Check for excessive inlet pressure or air
pressure.
Consult Chemical Resistance Chart for
compatibility with products, cleaners,
temperature limitations and lubrication.
Pump Blows Air Out Main Air
Exhaust When Idle
Pilot valve assembly stuck or
damaged.
Check pilot valve assembly, valve plate
and/or seals for wear and debris.
Sleeve and O Ring damaged. Check sleeve and O ring on diaphragm
connecting rod.
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EN13. DIAPHRAGM PUMPS
HOW DO I TROUBLESHOOTING A DIAPHRAGM PUMP WET SECTION?
Problem Cause Correction
Leaking at Bolts Old/worn/stretched bolts do not
produce a tight seal.
Replace bolts. Check for lock tight or
lock washers being used.
Stuck Open Ball Checks Checks cannot seat properly. Fluid
pressure will be reduced or eliminated. Clean or replace ball check assembly.
Fluid Compatibility Incompatibility can reduce life of pump.
Consult Chemical Resistance Chart for
compatibility with products, cleaners,
temperature limitations and lubrication.
Under Sizing Pump cannot meet application
requirements which leads to a shorter
pump life. (Due to high cycle rates)
Consult pump specifications in manual.
Pump Will Not Prime Or Meet
Delivery Requirements
Suction line blocked or undersized,
clogged ball seats. Clean or replace ball check assembly.
Suction line too long. Reduce pump suction line distance.
Suction line pulling material too far
above top of fluid level. Check suction tube level in material.
Air Bubbles In Product Discharge Introducing air from bad seal.
Check connections of suction plumbing.
Check O rings between intake manifold
and fluid caps.
Low Output Volume
Lack of supply air to pump. Check air at main supply.
Failed back pressure regulator or
blockage.
Check back pressure regulator settings
and plugged outlet hose.
Pump mounted in vertical stroke
position. Change stroke position to horizontal.
Cavitation occurs when material is
exiting the pump faster than can be
drawn in.
Check for pump cavitation - Suction pipe
minimum 1/2 and non-collapsible.
Loose connections or joints.
Check all intake & suction joints - Must
be airtight. (Use Teflon tape or sealant if
necessary.)
Stuck or closed ball checks. Check for sticking or improperly seating
check valves.
DANGER
Aluminum pumps may violently react with materials containing HHC (Hologenated Hydrocarbon) solvents, ie. Carbon
Tetrachloride.
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EN 14. HIGH PRESSURE SPRAYING: AIRLESS & AIR ASSIST AIRLESS
INTRODUCTION
High pressure spray equipment will typically use between
300 and 4000 psi of fluid pressure. Low pressure
equipment (air spray and HVLP) typically use 5-30 psi.
When high volume applications and heavy film builds are
called for, high pressure equipment excels.
Airless and air assist airless spray guns are used in high
pressure finishing. Also required is a pump capable of
delivering the pressures required for high pressure guns.
Other equipment concerns are hoses, regulators, filters,
heaters and any other equipment that is subjected to the
pressures being used and must be rated to handle the
pressure.
1. WHAT ARE THE ADVANTAGES OF HIGH
PRESSURE FINISHING?
• Speed of Application. (Due to the high flow rates, high
pressure equipment will be considerably faster than
low pressure equipment.)
• Improved Transfer Efficiency.
• Little or no air in the spray pattern.
• Sprays Most Coatings.
• Cost for high volume and high film build applications.
2. WHAT ARE THE DISADVANTAGES OF HIGH
PRESSURE FINISHING?
• Safety issues must be addressed.
• More training is required.
• Limited equipment flexibility.
• Unlike low pressure equipment, cup guns, feathering
the trigger and pattern adjustment are not available.
• Higher Initial Costs: high pressure equipment must be
able to handle the higher pressures used. In addition,
pumps are required to generate the pressures.
• Not For Small Quantities: high pressure equipment
flow rates are generally rated in gallons per minute,
low pressure equipment in ounces per minute.
• Plugging Tips: Due to the small opening in the fluid
tip, plugging is not uncommon in high pressure
equipment. Treatment and prevention for plugging
may be found in the troubleshooting section of this
manual.
• Heat may be required for high solids coatings: When
using today’s higher solid materials, heating of the
material to lower the viscosity may be required to
achieve the atomization required.
• Not For Fine Finish: The atomization capabilities of
high pressure equipment will not allow it to obtain an
automotive finish. Acceptability will depend on the
finish standards of the product being sprayed as well
as the characteristics of the coating.
SAFETY
3. WHAT ARE THE SAFETY CONCERNS WITH
HIGH PRESSURE EQUIPMENT?
• Skin Injection: high pressure equipment has the
capability of injecting coating into fingers, hands, etc.
• Supporting Equipment: Insure that all supporting
equipment is rated for the pressures that could be
generated. Use the maximum pump pressure as a
guide.
WARNING
INJECTION HAZARD
Spray from the gun, hose leaks, or ruptured
components can inject fluid into your body and cause
extremely serious injury, including poisoning or the need
for amputation.
Splashing fluid in eyes or on skin can also cause a
serious injury.
Fluid injected into the skin might look like just a cut, but
is a serious injury and should be treated as such.
GET IMMEDIATE MEDICAL ATTENTION.
INFORM THE PHYSICIAN WHAT TYPE OF
MATERIAL WAS INJECTED.
Do not point the spray gun at anyone or any part of the
body.
Do not put fingers or hand over the spray tip.
Do not stop or detect fluid leaks with a rag, hand, body
or glove.
Do not use a rag to blow back fluid.
THIS IS NOT AN AIR SPRAY GUN.
Be sure the trigger operates safely before spraying.
Engage the gun safety when not spraying.
ALWAYS RELIEVE THE PRESSURE WHENEVER
WORKING ON THE SPRAY GUN.
Tighten all fluid connections before operating
equipment.
Check all hoses, tubes, and couplings daily. Replace all
worn, damaged, or loose parts immediately.
SAFETY
Follow all safety instructions included with the
equipment. Use tip guards and trigger locks where
appropriate.
SAFETY
Respirators: Use the appropriate protection device as
listed in the coating’s Safety Data Sheet (SDS).
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EN14. HIGH PRESSURE SPRAYING: AIRLESS & AIR ASSIST AIRLESS
AIRLESS AND AIR ASSIST AIRLESS GUNS
High pressure spraying requires the use of spray guns
that can withstand the pressures associated with the
pressures delivered via piston pumps.
Airless and Air Assisted Airless are currently available in
both manual and automatic models.
Some models may have maximum pressures below the
pressures the pumping system may deliver.
Consult your distributor to determine your pump.
1. WHAT IS AN AIRLESS GUN?
An airless gun uses high hydraulic pressure to force
coating through a small elliptical shaped orifice to
atomize.
2. WHAT DO I NEED TO KNOW TO CHOOSE AN
AIRLESS FLUID TIP?
The following will determine pattern size and atomization:
• Fluid tip orifice shape
• Fluid tip orifice area
• Fluid viscosity
• Fluid pressure
Fluid tips for airless guns are sized based on an
equivalent circular opening.
As an example, a .015 opening can take on many
different shapes, thus different pattern sizes and
atomization levels.
For example, Table 1 shows 7 different .015 fluid tips
available for one model of an airless spray gun.
The shape of the opening is the variable that determines
the pattern size.
3. HOW DOES AN AIRLESS GUN OPERATE?
An airless spray gun uses high hydraulic fluid pressure
generated by a pump. The fluid is forced through a
small elliptical shaped orifice (fluid tip or fluid nozzle) to
generate the pattern.
4. WHAT IS AN AIR ASSIST AIRLESS GUN?
When air assist airless gun (see Figure 4) is set up with
pressures under 2000 psi, the possibility of incomplete
atomization increases. The net result is a pattern that
has tails at the top and bottom. If sprayed with such a
pattern, one would see a stripe at the top and bottom of
each pass (see figure 2).
An air cap similar to a conventional or HVLP spray gun
is added to a high pressure spray gun, thus the name Air
Assist Airless. Set the pressure on the assist air is set
high enough to eliminate the tails. (see figure 3)
NOTICE
The larger pattern sizes are the result of a tip opening
that is more slender than the shorter pattern tip. This
will give a larger pattern size at the expense of more
frequent tip plugging and shorter tip life.
Table 1: Different .015 Fluid Tip Sizes
Part Number Size Pattern Width
114-01506 .015 4 – 6
114-01508 .015 6 – 8
114-01510 .015 8 – 10
114-01512 .015 10 – 12
114-01514 .015 12 – 14
114-01516 .015 14 – 16
114-01518 .015 16 – 18
Figure 1: Airless Spray Gun
Figure 4: Air Assist Gun
Figure 2: Incomplete Atomization Figure 3: Air Assist
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EN 15. TWO BALL PISTON PUMPS AND DEAD END SYSTEMS
INTRODUCTION
A pump is required to generate the pressures required for
airless and air assist airless spray guns.
The most common pump used to supply high pressure
spray guns is an air driven two ball piston pump.
1. HOW ARE PISTON PUMP PRESSURES
DETERMINED?
Pump ratios are determined by the size of the piston in
the air motor compared to the size of the piston in the fluid
section.
The maximum pump pressure available from a pump is
the ratio of the pump multiplied by the maximum air inlet
pressure as stated in the pump literature.
As an example, consider a piston pump with an 8 air
motor and a 2 fluid section:
8 = 50.24 square inch area
2 = 3.14 square inch area
50.24/3.14 = 16:1 ratio
If the pump had a maximum air inlet pressure of 100 psi,
the maximum fluid pressure the pump could generate is
1600 psi.
2. WHAT RATIO DO I NEED FOR MY SPRAY GUN?
It is generally recommended that the maximum usable
pressure is approximately 60-70% of the maximum pump
pressure. A spray gun that requires 1000 psi of fluid
pressure would need approximately an 18:1 pump (60%
times 1800 psi would give 1080 psi of working pressure.
Other factors that influence ratio selection include:
• Gun distance from pump (pressure drop).
• Circulation requirements (if used).
• Viscosity of material.
• Size of fluid tip in gun.
• Pipe layout
3. WHAT IS MEANT BY PRIMING THE PUMP?
Before setting working fluid pressures, start an empty
pump by slowly opening the air pressure valve (or
regulator) to the air motor. When the pump no longer
cycles (full of coating), adjust the regulator to set the
fluid pressure to the working pressure.
If the air motor receives full working pressure with an
empty fluid section, the fluid section contains air and will
initially run at high speed with no lubrication. This will
increase the risk of friction/heat damaging the packings
and/or fluid section.
4. HOW DOES A TWO BALL FLUID SECTION
WORK?
The fluid section is connected to the air motor. As the
air motor moves up (1 stroke) it brings the displacement
rod up. As the air motor moves down, it pushes the
displacement rod down.
During the upstroke, the lower ball (B) raises allowing
coating to enter the lower portion of the fluid section.
Coating in the upper portion of the fluid section is pushed
out of the outlet. The upper ball (A) remains closed. (see
Figure 2)
During the downstroke, the lower ball remains closed.
The upper ball is forced open allowing coating from the
lower portion of the pump to enter the upper portion
pushing coating out of the outlet.
If the pump is designed properly, 50 percent of the
pumps output will be delivered on each stroke. (one
upstroke, one downstroke). Note that with most 2 ball
pumps all of the coating siphoned into the pump for the
complete cycle enters the fluid section on the upstroke.
Figure 1: Two Ball Piston Pump
Figure 2: Two Ball Fluid Section
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EN15. TWO BALL PISTON PUMPS AND DEAD END SYSTEMS
1. HOW DO I SETUP A SIMPLE (DEAD-END) HIGH
PRESSURE SYSTEM?
Refer to Figure 3 for a typical dead end high pressure
system.
1. 2 Ball Piston Pump Available in range of approximately
11:1 to 60:1
2. Filter/Regulator for Pump air motor. The air motor of a
piston pump needs to be supplied with clean, dry air.
3. Surge tank (pulsation chamber) eliminates pulsation
that happens when the piston changes direction.
4. Dual Fluid Filters prevents the line from being shut
down when it is time to clean the filter.
5. Fluid pressure gauge monitors the fluid pressure in the
main line.
6. Drop Line regulator allows for regulation to the required
pressure of the spray gun.
2. WHAT PARAMETERS IN A DEAD-END SYSTEM
SHOULD BE OF CONCERN?
• Use only components that can handle the pressures
in the system. This includes all components in figure
3 as well as hoses, guns, fittings, etc.
• Fluid lines must be sized adequately to prevent large
pressure losses.
• When using coating materials that settle out or
high viscosity materials that need to be heated, a
circulating system may be a better option.
3. HOW FAST OR SLOW SHOULD MY PUMP BE
CYCLING?
Most pumps give a flow rate per cycle as well as a flow
rate for 60 cycles. A flow rate of 15 cycles per minute will
keep maintenance to a minimum. As you increase cycle
speed, maintenance cost will increase as well.
If you undersize a pump, high cycle rates and high
maintenance costs will be the result.
4. WHAT SAFETY ISSUES SHOULD BE
ADDRESSED IN A HIGH PRESSURE SYSTEM?
• All components in the systems must be rated to
handle the maximum pressure the pump could
generate.
• Avoid the possibility of any portion of the body being
near the fluid tip whenever there is a chance of fluid
leaving the tip. If you inject your skin with coating,
seek medical help immediately.
• If the gun is equipped with a trigger safety, engage it
when the gun is not in use.
• If the gun is equipped with a tip guard (duck bill), do
not remove it.
5. WHAT IS THE PURPOSE OF THE WET CUP?
Lubrication for the upper packings is provided by a
lubricant added to the Wet Cup at the upper portion
of the fluid section. This cup is not designed to contain
solvent. Solvent will evaporate, leaving the upper
packings without lubricant. Throat Seal Lubricant (TSL)
should be used in the wet cup with the appropriate
specification depending on water or solvent based
materials being used.
6. WHAT IS MEANT BY CAVITATION?
A pump has little difficulty pushing material through the
outlet into the piping or tubing system.
If the pump cannot bring material into the pump as fast
as it pushes it out, a cavity or void is created in the input
area. This could result if the material is highly viscous or
the siphon tube is undersized or not airtight.
DEAD END SYSTEMS
Proper setup of high pressure equipment is necessary
not only for efficient operation of the equipment, but safe
operation as well.
Airless and Air Assist Airless may be supplied by a dead
end system or a circulating system.
Following are instructions for a deadend system.
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EN 15. TWO BALL PISTON PUMPS AND DEAD END SYSTEMS
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EN15. TWO BALL PISTON PUMPS AND DEAD END SYSTEMS
TROUBLESHOOTING
Problems arising in a high pressure pumping system can range from something as simple as a plugged fluid tip to a
runaway pump. Service literature that accompanies your equipment is highly recommended reading.
HOW DO I TROUBLESHOOTING A HIGH PRESSURE DEAD END SYSTEM?
Problem Cause Correction
Gun
Plugged Airless Tips Material builds up on orifice of tip.
Clean and/or replace tip orifice.
Use only recommended tools to clean a
plugged tip.
Defective Spray Pattern
Airless: Worn out or dirty tip.
Air Assist Airless: Worn out of dirty
aircap and or fluid tip.
Airless: Replace or clean tip.
Air Assist Airless: Rotate the air cap 180
degrees. If the pattern changes, clean or
replace the air cap. If the pattern did not
change, clean or replace the fluid tip.
Pump Runaway Pump
When the material supply runs
out, the pump will cycle at
maximum speed.
Install a runaway detecting valve on the air
line between the air motor and regulator to
prevent damage to the pump.
Air
Motor
Air Leakage Out Of Main
Exhaust
Worn insert.
Worn valve plate & pilot valve assy.
Damaged piston assy.
Check all three parts and replace if worn.
Fluid
Section
No Material At Outlet
(Pump Continually
Cycles)
Lack of supply material. Check material supply.
Material On One Stroke
Only (Fast Down Stroke) Lower ball not properly seating. Check lower balls and replace if worn.
Material On One Stroke
Only (Fast Upstroke) Worn or damaged seals. Check seals and replace if worn.
Material Leakage Form
Solvent Cup
Worn or improperly adjusted upper
packings.
Check packings and adjustment nut and
tighten or replace if worn.
Air Bubbles In Product
Discharge
Siphon kit improperly installed (not
air tight). Check siphon kit for proper installation.
DANGER
Before maintenance or repair of the high pressure system, be certain all pressure is completely vented from the
pump, suction, discharge, piping, and all other openings and connections. Be sure the air supply is locked out
or made non‑operational, so that it cannot be started while work is being done on the system. Be certain that
approved eye protection and protective clothing are worn all times in the vicinity of the pump. Failure to follow these
recommendations may result in serious injury or death.
WARNING
At a minimum, lock the trigger before working on a high pressure airless fluid tip. If possible, remove the pressure
to the gun.
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EN 16. FOUR BALL PISTON PUMPS AND CIRCULATING SYSTEMS
INTRODUCTION
A four ball pump generally is used in a pump house
or paint kitchen for delivering lower pressures a long
distance or high flow rates.
Pressures tend to be much lower than 2 ball pumps
and are often regulated down at the point of use for air
atomized spray guns.
1. WHAT RATIOS ARE AVAILABLE IN A FOUR BALL
PUMP?
Due to the larger fluid section, a very large air motor
would be required to achieve the typical pressures
achieved with two ball pumps. Using the same air motors
used in two ball pumps, four ball pumps typically top out
at a 25:1 ratio.
2. HOW DOES A FOUR BALL FLUID SECTION
WORK?
A four ball piston pump fluid section contains four ball
checks that alternate open and closed during its strokes
(refer to figure 2).
During a pressure stroke, ball checks (D) and (A) open.
Ball (A) allows fluid to exit at pressure on one side of
the pump, while ball (D) allows fluid to enter the pump to
siphon fill.
Ball checks (B) and (C) remain closed to generate outlet
fluid pressure.
During the change over, (D) and (A) close, while (C) and
(B) open to allow fluid to exit at pressure on one side of
the pump, while ball (C) allows fluid to enter the pump to
siphon fill.
Ball checks (A) and (D) remain closed to generate outlet
fluid pressure.
Figure 1: Four Ball Piston Pump Figure 2: Four Ball Fluid Section
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EN16. FOUR BALL PISTON PUMPS AND CIRCULATING SYSTEMS
CIRCULATING SYSTEMS
A circulating system delivers fluid from the pump to the
spray gun and back to the pump. (see figure 3).
You should consider a circulating system:
• When multiple stations need the same coating.
• When you want to put a paint heater in the system (to
reduce viscosity without adding solvents).
• When you have problems with the solids of a coating
settling out.
1. WHAT FLOW RATES ARE USED IN A
CIRCULATING SYSTEM?
• Typical flow rates for solvent based materials are one
foot per second (60 feet/min).
• Typical water based materials use one half foot per
second (30 feet/min).
• Consult your Product Data Sheet or your coating
supplier for recommendations for your coating.
2. HOW DOES A CIRCULATING SYSTEM WORK?
While some circulating systems can get very complex,
refer to figure 3 for a very basic circulating system
The coating leaves the fluid section of the pump and
travels through hoses, pipes, etc. to the spray gun.
A valve or tee at the spray drop line returns a portion of
the material back to the pump on a return line.
The materials may return to the pump inlet or into the
material container.
3. WHAT IS A BACK PRESSURE REGULATOR?
Referring to figure 3, imagine the back pressure regulator
(3) removed from the system and the piping is straight
through back to the pump.
There would be no reason for the material to flow to the
spray gun as the path of least resistance for the material
is back to the pump.
By putting a back pressure regulator in the system we
create a dam that allows some fluid to return to source
but set up a partial blockade (back pressure) to allow
material to flow to the spray gun.
The general sequence for adjusting a back pressure
regulator is:
1. Set the regulator to insure that the spray guns have
adequate operating pressure.
2. Adjust for proper flow rate.
3. Adjust for proper pump speed.
4. WHAT OTHER COMPONENTS ARE USED IN A
CIRCULATING SYSTEM?
• Downstream Fluid Regulators: For controlling
pressure at each spray gun.
• Surge Tanks/Chambers: For suppressing the
wink or pulse in the system, induced by the pump
changing direction during the cycle.
• Heaters: For decreasing viscosity without adding
solvent and maintaining a constant viscosity.
• Filters: For removing contaminants and preventing
plugging gun fluid tips and spray defects.
• Strainers: For removing trash prior to entering the
pump.
• Drum Lifts/Elevators: Allows the pump and drum lid to
be raised to facilitate replacement of the drum.
• Agitator: Keeps material in suspension in the drum/
container.
NOTICE
Filters are located in the pressure side of the system.
NOTICE
Strainers are located on the non-pressure portion of the
system, normally on the end of the pump pick-up tube.
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EN 16. FOUR BALL PISTON PUMPS AND CIRCULATING SYSTEMS
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EN16. FOUR BALL PISTON PUMPS AND CIRCULATING SYSTEMS
TROUBLESHOOTING
Problems arising in a low pressure pumping system can range from something as simple as a plugged fluid tip to a
runaway pump. Service literature that accompanies your equipment is highly recommended reading.
HOW DO I TROUBLESHOOTING A LOW PRESSURE CIRCULATING SYSTEM?
Problem Cause Correction
Gun See Chapter 5 Air Atomizing Spray Guns For Troubleshooting
Material
Supply
Air Bubbles
Low Flow
Material Change
Low material level.
Suction point above paint line.
Agitator running to fast/slow.
Add material.
Install bottom outlet.
Agitator speeds not set correctly.
Circulation
Pump
Excessive Wear
Pressure/Volume Output
Pulsation
Pump Stalling
Over Pressure Faults
Reference pump manual, Cycle
rate limits.
Worn/damaged seals.
Dirty/stuck air controls.
Material blockage.
Inspect and repair pump.
Check main power and main air supply.
Inspect and repair fluid lines, fluid filters,
regulators and BPR.
System
Controls
Pump Won’t Run Or Pump
Settings Changed
PLC parameters restrict pump.
Main air or power supply issues.
BPR is closed.
Check set points/fault codes.
Check power/main compressor.
Check valves/regulators.
Circulation
Lines
Low Material Volume
Viscosity/Material
Changes
Fluid Pressure Changes
Circulation line restriction.
Pipe ID under sized.
Circulation speed settings
(suspension).
BPR faulty and/or piping/system
unbalanced.
Inspect and/or repair circulation system.
Inspect line distance and inspect speeds.
Inspect the number of drops/locations
from the supply to pump and/or to return.
Application
Point
Low or No Material
Winking or Pulsing
Air Being Observed
Pressure Fluctuations
Finish Quality
Applicators and circulation lines.
Paint filters and regulators.
Material supply level.
Pump seals and ball checks.
Paint viscosity/material change.
Check power and main air source.
Verify gun operation.
Verify circulation speed and pressure
settings.
Inspect for open suction connections.
Verify pump operation/material supply.
Material
Return
Low or No Material
Air Being Observed
Inconsistent Return Flow
System in demand (guns
triggered).
Paint supply low.
Air being introduced.
Inspect paint filters and regulators
Inspect BPR and system operation.
Verify system parameters and/or material
supply.
WARNING
At a minimum, remove the pressure at the pump before performing maintenance.
WARNING
Before maintenance or repair of the circulation system, be certain all pressure is completely vented from the pump,
suction, discharge, piping, and all other openings and connections. Be sure the air supply or power to the pump is
locked out or made non‑operational, so that it cannot be started while work is being done on the system. Be certain
that approved eye protection and protective clothing are worn all times in the vicinity of the pump. Failure to follow
these recommendations may result in serious injury or death.
EN 17. APPENDIX
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GUIDE TO USABLE SOLVENT SELECTION
Chemical Name Common Name Category Flash Point†† (TCC) *CAS No. Evap. Rate† Elec. Res.**
DICHLOROMETHANE Methylene Chloride Chlorinated Solvents - 75-09-2 14.5 HIGH
VM & P NAPHTHA Naphtha Aliphatic Hydrocarbons 65oF 8030-30-6 10 HIGH
ACETONE - Ketones -18oF 67-64-1 5.6 LOW
METHYL ACETATE - Esters 90oF 79-20-9 5.3 LOW
BENZENE - Aromatic Hydrocarbons 12oF 71-43-2 5.1 HIGH
ETHYL ACETATE - Esters 24oF 141-78-6 3.9 MEDIUM
2-BUTANONE MEK Ketones 16oF 78-93-3 3.8 MEDIUM
ISO-PROPYL ACETATE - Esters 35oF 108-21-4 3.4 LOW
ISOPROPYL ALCOHOL IPA Alcohols 53oF 67-63-0 2.5 LOW
2-PENTANONE MPK Ketones 104oF 107-87-9 2.5 MEDIUM
METHANOL Methyl Alcohol Alcohols 50oF 67-56-1 2.1 LOW
PROPYL ACETATE n-Propyl Acetate Esters 55oF 109-60-4 2.1 LOW
TOLUOL Toluene Aromatic Hydrocarbons 48oF 108-88-3 1.9 HIGH
METHYL ISOBUTYL KETONE MIBK Ketones 60oF 108-10-1 1.6 MEDIUM
ISOBUTYL ACETATE - Esters 69oF 110-19-0 1.5 LOW
ETHANOL Ethyl Alcohol Alcohols - 64-17-5 1.4 LOW
BUTYL ACETATE - Esters 78oF 123-86-4 1.0 LOW
ETHYLBENZENE - Aromatic Hydrocarbons 64oF 100-41-4 .89 HIGH
1-PROPANOL n-Propyl Alcohol Alcohols 74oF 71-23-8 .86 LOW
2-BUTANOL sec.-Butyl Alcohol Alcohols 72oF 78-92-2 .81 LOW
XYLOL Xylene Aromatic Hydrocarbons 79oF 133-02-07 .80 HIGH
AMYL ACETATE - Esters 106oF 628-63-7 .67 MEDIUM
2-METHYLPROPANOL iso-Butyl Alcohol Alcohols 82oF 78-83-1 .62 LOW
METHYL AMYL ACETATE - Esters 96oF 108-84-9 .50 LOW
5-METHYL-2-HEXANONE MIAK Ketones 96oF 110-12-3 .50 MEDIUM
1-BUTANOL n-Butyl Alcohol Alcohols 95oF 71-36-3 .43 LOW
2-ETHOXYETHANOL - Glycol Ethers 164oF 110-80-5 .38 LOW
2-HEPTANONE MAK Ketones 102oF 110-43-0 .40 MEDIUM
CYCLOHEXANONE - Ketones 111oF 108-94-1 .29 MEDIUM
AROMATIC-100 SC#100 Aromatic Hydrocarbons 111oF - .20 HIGH
DIISOBUTYL KETONE DIBK Ketones 120oF 108-83-8 .19 MEDIUM
1-PENTANOL Amyl Alcohol Alcohols - 71-41-0 .15 LOW
DIACETONE ALCOHOL - Ketones 133oF 123-42-2 .12 LOW
2-BUTOXYETHANOL Butyl Cellosolve Glycol Ethers 154oF 111-76-2 LOW
CYCLOHEXANOL - Alcohols 111oF 108-93-0 .05 LOW
AROMATIC-150 SC#150 Aromatic Hydrocarbons 149oF - .004 HIGH
AROMATIC-200 - Aromatic Hydrocarbons 203oF - .003 HIGH
PAINT AND SOLVENT SPECIFICATIONS
AEROBELL® 33
Ransflex NO.2 HANDGUN TURBODISK™ AEROBELL® 168 RMA 600 Series
AEROBELL® 268
RECOMMENDED VISCOSITY USING A ZAHN NO. 2 18 TO 30 SEC 20 TO 60 SEC 20 TO 60 SEC 20 TO 60 SEC 20 TO 60 SEC
PAINT ELECTRICAL RESISTANCE** .1 MΩ TO ∞ .1 TO 1 MΩ .1 MΩ TO ∞ .1 MΩ TO ∞ .1 MΩ TO ∞
RECOMMENDED DELIVERY (UP TO) 1000 cc/min 180 cc/min 1000 cc/min 500 cc/min 1000 cc/min***
*CAS Number: Chemical Abstract Service Number.
**Electrical Resistance using the Ransburg Meter.
***See product manual for fluid rates per bell cup configurations.
†Information Obtained From: http://solvdb.ncms.org
††The lowest temperature at which a volatile fluid will ignite.
Evaporation Rate is Based Upon Butyl Acetate Having a Rate of 1.0
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VISCOSITY CONVERSION CHART
.1 10 27 11 20 - - 5 A-4 - - 60 30 16 - - - - 10
.15 15 30 12 25 - - 8 A-3 - - 80 34 17 - - - - 11
.2 20 32 13 30 15 12 10 - - - 100 37 18 - - - - 12
.25 25 37 14 35 17 15 12 A-2 - - 130 41 19 - - - - 13
.3 30 43 15 39 18 19 14 A-1 - - 160 44 20 - - - - 14
.4 40 50 16 50 21 25 18 A - - 210 52 22 - - - 19 15
.5 50 57 17 - 24 29 22 - - 30 260 60 24 - - - 20 16
.6 60 64 18 - 29 33 25 B - 33 320 68 27 - - - 21 18
.7 70 - 20 - 33 36 28 - - 35 370 - 30 - - - 23 21
.8 80 - 22 - 39 41 31 C - 37 430 - 34 - - - 24 23
.9 90 - 23 - 44 45 32 - - 38 480 - 37 10 - - 26 25
1.0 100 - 25 - 50 50 34 D - 40 530 - 41 12 10 - 27 27
1.2 120 - 30 - 62 58 41 E - 43 580 - 49 14 11 - 31 31
1.4 140 - 32 - - 66 45 F - 46 690 - 58 16 13 - 34 34
1.6 160 - 37 - - - 50 G - 48 790 - 66 18 14 - 38 38
1.8 180 - 41 - - - 54 - 000 50 900 - 74 20 16 - 40 43
2.0 200 - 45 - - - 58 H - 52 1000 - 82 23 17 10 44 46
2.2 220 - - - - - 62 I - 54 1100 - - 25 18 11 - 51
2.4 240 - - - - - 65 J - 56 1200 - - 27 20 12 - 55
2.6 260 - - - - - 68 - - 58 1280 - - 30 21 13 - 58
2.8 280 - - - - - 70 K - 59 1380 - - 32 22 14 - 63
3.0 300 - - - - - 74 L - 60 1475 - - 34 24 15 - 68
3.2 320 - - - - - - M - - 1530 - - 36 25 16 - 72
3.4 340 - - - - - - N - - 1630 - - 39 26 17 - 76
3.6 360 - - - - - - O - 62 1730 - - 41 28 18 - 82
3.8 380 - - - - - - - - - 1850 - - 43 29 19 - 86
4.0 400 - - - - - - P - 64 1950 - - 46 30 20 - 90
4.2 420 - - - - - - - - - 2050 - - 48 32 21 - 95
4.4 440 - - - - - - Q - - 2160 - - 50 33 22 - 100
4.6 460 - - - - - - R - 66 2270 - - 52 34 23 - 104
4.8 480 - - - - - - - 00 67 2380 - - 54 36 24 - 109
5.0 500 - - - - - - S - 68 2480 - - 57 37 25 - 112
5.5 550 - - - - - - T - 69 2660 - - 63 40 27 - 124
6.0 600 - - - - - - U - 71 2900 - - 68 44 30 - 135
7.0 700 - - - - - - - - 74 3375 - - - 51 35 - 160
8.0 800 - - - - - - - 0 77 3380 - - - 58 40 - 172
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VISCOSITY CONVERSION CHART (cont.)
9.0 900 - - - - - - V - 81 4300 - - - 64 45 - 195
10.0 1000 - - - - - - W - 85 4600 - - - - 49 - 218
11.0 1100 - - - - - - - - 88 5200 - - - - 55 - -
12.0 1200 - - - - - - - - 92 5620 - - - - 59 - -
13.0 1300 - - - - - - X - 95 6100 - - - - 64 - -
14.0 1400 - - - - - - - 1 96 6480 - - - - - - -
15.0 1500 - - - - - - - - 98 7000 - - - - - - -
16.0 1600 - - - - - - - - 100 7500 - - - - - - -
17.0 1700 - - - - - - - - 101 8000 - - - - - - -
18.0 1800 - - - - - - Y - - 8500 - - - - - - -
19.0 1900 - - - - - - - - - 9000 - - - - - - -
20.0 2000 - - - - - - - - 103 9400 - - - - - - -
21.0 2100 - - - - - - - - - 9850 - - - - - - -
22.0 2200 - - - - - - - - - 10300 - - - - - - -
23.0 2300 - - - - - - Z 2 105 10750 - - - - - - -
24.0 2400 - - - - - - - - 109 11200 - - - - - - -
25.0 2500 - - - - - - Z-1 - 114 11600 - - - - - - -
30.0 3000 - - - - - - - - 121 14500 - - - - - - -
35.0 3500 - - - - - - Z-2 3 129 16500 - - - - - - -
40.0 4000 - - - - - - - - 133 18500 - - - - - - -
45.0 4500 - - - - - - Z-3 - 136 21000 - - - - - - -
50.0 5000 - - - - - - - - - 23500 - - - - - - -
55.0 5500 - - - - - - - - - 26000 - - - - - - -
60.0 6000 - - - - - - Z-4 4 - 2800 - - - - - - -
65.0 6500 - - - - - - - - - 30000 - - - - - - -
70.0 7000 - - - - - - - - - 32500 - - - - - - -
75.0 7500 - - - - - - - - - 35000 - - - - - - -
80.0 8000 - - - - - - - - - 37000 - - - - - - -
85.0 8500 - - - - - - - - - 39500 - - - - - - -
90.0 9000 - - - - - - - - - 41000 - - - - - - -
95.0 9500 - - - - - - - - - 43000 - - - - - - -
100.0 10000 - - - - - - Z-5 5 - 46500 - - - - - - -
110.0 11000 - - - - - - - - - 51000 - - - - - - -
120.0 12000 - - - - - - - - - 55005 - - - - - - -
130.0 13000 - - - - - - - - - 60000 - - - - - - -
140.0 14000 - - - - - - - - - 65000 - - - - - - -
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Se
ar
s
C
ra
fts
m
an
C
up
D
in
C
up
4
Po
is
e
EN17. APPENDIX
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VISCOSITY CONVERSION CHART (cont.)
150.0 15000 - - - - - - Z-6 - - 67500 - - - - - - -
160.0 16000 - - - - - - - - - 74000 - - - - - - -
170.0 17000 - - - - - - - - - 83500 - - - - - - -
180.0 18000 - - - - - - - - - 83500 - - - - - - -
190.0 19000 - - - - - - - - - 88000 - - - - - - -
200.0 20000 - - - - - - - - - 93000 - - - - - - -
300.0 30000 - - - - - - - - - 140000 - - - - - - -
C
en
tip
oi
se
Pa
rli
n
7
Pa
rli
n
10
Fi
sh
er
1
Fi
sh
er
2
Fo
rd
C
up
3
Fo
rd
C
up
4
G
ar
dn
er
-H
ol
dt
B
ub
bl
e
Li
th
og
ra
ph
ic
Kr
eb
s
U
ni
tK
U
Sa
yb
ol
t U
ni
ve
rs
al
S
SU
Za
hn
1
Za
hn
2
Za
hn
3
Za
hn
4
Za
hn
5
Se
ar
s
C
ra
fts
m
an
C
up
D
in
C
up
4
Po
is
e
VOLUMETRIC CONTENT OF HOSE OR TUBE (English units)
I.D. (inches) cc/ft. Cross Section
(sq. in.)
Length
5 ft. (60) 10 ft. (120) 15 ft. (180) 25 ft. (300) 50 ft. (600)
1/8 2.4 .012 .003 gal.
.4 fl. oz.
.006 gal.
.8 fl. oz.
.010 gal.
1.2 fl. oz.
.016 gal.
2.0 fl. oz.
.03 gal.
4.0 fl. oz.
3/16 5.4 .028 .007 gal.
.9 fl. oz.
.014 gal.
1.8 fl. oz.
.022 gal.
2.7 fl. oz.
.036 gal.
4.5 fl. oz.
.072 gal.
9.0 fl. oz.
1/4 9.7 .049 .013 gal.
1.6 fl. oz.
.025 gal.
3.2 fl. oz.
.038 gal.
4.8 fl. oz.
.064 gal.
8.0 fl. oz.
.127 gal.
16.0 fl. oz.
5/16 15.1 .077 .020 gal.
2.5 fl. oz.
.040 gal.
5.1 fl. oz.
.060 gal.
7.6 fl. oz.
.100 gal.
12.7 fl. oz.
.199 gal.
25.5 fl. oz.
3/8 21.7 .110 .029 gal.
3.7 fl. oz.
.057 gal.
7.3 fl. oz.
.086 gal.
11.0 fl. oz.
.143 gal.
18.4 fl. oz.
.287 gal.
36.7 fl. oz.
1/2 38.6 .196 .051 gal.
6.5 fl. oz.
.102 gal.
13.1 fl. oz.
.153 gal.
19.6 fl. oz.
.255 gal.
3.6 fl. oz.
.510 gal.
65.3 fl. oz.
VOLUMETRIC CONTENT OF HOSE OR TUBE (Metric units)
I.D. (mm) cc/m Cross Section
(mm2)
Length
1.5 m 3.0 m 4.5 m 6.0 m 7.5 m
3.6 102 10.2 15.3 cc 30.5 cc 45.8 cc 61.1 cc 76.3 cc
5.6 246 24.6 36.9 cc 73.9 cc 110.8 cc 147.8 cc 184.7 cc
6.8 363 36.3 54.4 cc 109.0 cc 163.4 cc 217.9 cc 272.4 cc
8.8 608 60.8 91.2 cc 182.5 cc 273.7 cc 364.9 cc 456.2 cc
Note: All viscosity comparisons are as accurate as possible with existing information.
Comparisons are made with a material having a specific gravity of 1.0.
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EN EN 18. MANUAL REVISIONS
MANUAL CHANGE SUMMARY
Date Description Version
02/2025
Updated to new template, rebranded to Binks, added electrostatic powder
application, additional electrostatic applicator pictures, transfer efficiency chart,
threaded styles for pipe, circulating system troubleshooting and appendix
information.
R2
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EN EN18. MANUAL REVISIONS
NOTES
www.binks.com 1-239-E-R2 (02/2025) 67 / 68
EN 19. CONTACT INFORMATION
For technical assistance or to locate an authorized distributor, contact one of our international sales
and customer support locations listed below.
REGION BINKS CONTACT
Americas Tel: 1-800-992-4657
Europe, Africa, Middle East Tel: +4401202571111
India marketingroa@binks.com
China Tel: +862133730108
Korea Tel: +82313663303
Japan Tel: +81457856421
Australia Tel: +61085257555
EN
©2025 Binks US, LLC. All rights reserved.
Binks is a global leader in innovative finishing technologies.
Binks reserves the right to modify equipment specifications without prior notice.
Binks®, DeVilbiss® and Ransburg® are registered trademarks of Binks US, LLC.
®
