Pittsburgh Spray Equipment Company. The Complete Guide to Painting Equipment

Transcription

1 Pittsburgh Spray Equipment Company The Complete Guide to Painting Equipment

2 Table of Contents 1. Airless Paint Sprayers Tails Their Causes and Solutions 2. Should You Repair your own Airless Paint Sprayer-A Decision Guide 3. Pressure pots VS Airless Paint Sprayer s A Complete Guide 4. Latex Paint Spraying Guide 5. HVLP Versus Airless Paint Sprayer A Guide 6. HVLP Spray Gun FAQ's 7. Is Powder Coating More Durable Than Paint - A Guide 8. Distance You Should Hold A Spray Gun from a Product, A Complete Guide (Infographic) 9. How often To Change Paint Booth Filters - A Guide 10. How to Fix a Dripping or Leaking Spray Gun 11. A Guide to Powder Coating Over an Existing Coating 12. Can you Powder Coat in a Liquid Paint Booth 13. Paint Pressure Pot Problems - Causes and Solutions 14. Understanding Theoretical Coverage Rate of Coatings 15. Refrigerant vs Desiccant Air Dryers 16. EPA Compliant Spray Guns- What You Should Know

3 17. Infrared vs Convection Ovens for Paint Curing 18. Air Assisted Airless Versus HVLP 19. How to Use a Wet Film Gauge 20. Spray Gun Compressed Air Filter Guide 21. Choosing a Pressure Pot for Painting 22. Spray Gun Air Cap Selection Guide 23. A Complete Guide to Keeping a Paint Booth Clean 24. Choosing an Airless Paint Sprayer Tip (Along with Calculator) 25. How to Know CFM for a Paint Booth & Exhaust Fan Size 26. How to Choose A Spray Gun Fluid Nozzle Size 27. How Much Does A Paint Booth Cost, A Complete Cost Guide 28. How Much Does a Paint Gun Cost, A Complete Guide Based on Different Gun Types 29. How Much Paint Will A Gallon of Hand Applied or Sprayed Paint Cover 30. HVLP Spray Gun Problems and Their Solutions 31. HVLP Turbine Vs Compressor HVLP Spray Gun 32. Gravity Feed Spray Guns vs Suction Feed Spray Guns 33. Electrostatic Paint Sprayer and Spray Guns Their Pro's and Cons 34. Complete Guide to Buying Used Spray Guns on Ebay or Craigslist

4 35. Cross draft vs Downdraft vs Side Downdraft Paint Booths 36. Choosing an Air Compressor for Airless Paint Sprayers and Spray Guns 37. Airless Paint Sprayer Troubleshooting 38. Choosing an Airless Paint Sprayer 39. HVLP Spray Gun Vs Conventional Spray Gun VS LVMP 40. HVLP, LVMP, and Conventional Air Caps the Advantages and Disadvantages of Each 41. Important Considerations for Spraying Waterborne Coatings 42. How to Avoid Spray Equipment Breakdown 43. How to Maintain Your Spray Equipment 44. Spraying Coatings vs Hand Applying Coatings 45. When to use Conventional Spray Guns vs Airless Paint Sprayers 46. Documentation Saves Time and Money in Spraying Applications 47. How to Know if You Need an Air Make Up Unit for Your Paint Booth 48. When is an Electrostatic Spray Gun a Good Fit for my Coating Application 49. How to Extend the Life of Your Spray Guns Fluid Needle and Nozzle 50. Selecting the Right Fluid Nozzle for your Spray Gun

5 51. Common Paint and Stain Finish Quality Issues and Their Solutions 52. Reduce Your Coating Costs by Maximizing Transfer Efficiency 53. How you can Ruin the Benefit of HVLP Spray Guns 54. How to Adjust Spray Guns for Optimum Finishing 55. How to Clean a Spray Gun 56. The Various Differences in Spray Gun Prices, Why they Exist 57. Need additional Help?

6 Airless Paint Sprayers Tails Their Causes and Solutions What is an Airless Paint Sprayer Tail? An airless paint sprayer tail is when the edges of your airless paint sprayers pattern do not remain uniform compared to the rest of your airless paint sprayers fan. The end result is lines at the edges of your spray pattern. Visually Airlesss Tails can be seen in the photo below. You can also view an additional picture of tails here. What Causes Airless Paint Sprayer Tails? Airless Paint Sprayer tails occur because the paint is not being evenly atomized by the fluid being forced through your airless paint sprayers fluid tip. There are a few different solutions to the problem of airless paint sprayer tails. Potential Fixes for Airless Paint Sprayer Tails

7 1. Increase the pressure on your airless paint sprayer The most common cause of tails on an airless paint sprayer s pattern is that the pressure is not turned up high enough to provide adequate even atomization of your coating throughout the pattern. The first thing to try is always to increase the pressure on your airless paint sprayer. 2. Thin Your Paint If increasing the pressure on the airless paint sprayer doesn t work, you can try to add a little bit of an appropriate thinner to your paint. By using thinner paint less pressure will result in a greater break up of the coating which should help to reduce issues with tails. 3. Clean your airless paint spray tip-if you have not recently cleaned the airless tip or the airless sprayer has been in storage for a while, you want to use an appropriate thinner to clean off the tip. If thinner does not remove any buildup on the tip, you may need to replace the tip. This is because any obstruction on your airless paint sprayers tip, will result in issues in your spray pattern. 4. Check the distance at which you are spraying from the surface product- For airless Paint sprayers the recommended distance is usually inches. If you spray to close you can get fingers, if you move to slow you can get issues with puddling and fingers as well. 5. Give the tip time to break in A tip can sometimes need a bit of time to break in and spray appropriately if you have tried a variety of the other suggestions spraying on a surface that requires a less fine finish may be a good idea to see if the tip needs to be used a while. 6. Consider a Fine Finish Airless Tip A Fine finish airless tip brings the material through two restrictions causing an additional level of atomization. The downside to a fine finish tip is that they may not last as long as a traditional airless paint sprayer tip. 7. Consider Air Assist Airless If you routinely need finer atomization for your application, maybe because it is for wood finishing or an application that requires higher quality finishes, you may want to consider an air assist airless as the assist air will remove the fingers in your spray pattern. 8. Use high quality paints Often times higher quality paints will have less chance of plugging your airless tip which will help reduce problems with tails. 9. Check your airless paint sprayers Stroke An airless paint sprayer should have a crisp even stroke if it is not consistent throughout its stroke, your packings or balls and seats may be worn causing issues with consistent pressure. Without consistent pressure you could experience tails. Conclusion By considering these 8 tips you should be able to resolve the issue with your airless paint sprayer giving you tails. By eliminating tails you can achieve better finishes.

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9 Should You Repair your own Airless Paint Sprayer-A Decision Guide Airless paint sprayers are the backbone of a paint contractor s business, if they fail it can end up costing you significant money. However, repair services can often be expensive and take time to have your repair work finished depending on how busy the repair store is. In this article will cover things to think about when you re evaluating whether not to repair your own airless paint sprayer or have an outside company do the work for you. Factors to consider when Evaluating Repairing an Airless vs having A Outside Company Repair Airless Paint Sprayer 1. The Number of Airless Paint Sprayers You Own - if you have multiple airless paint sprayers and have multiple crew members who work for you it is often easier to be able to send your airless paint sprayer to repair company. After all, you will not have to worry about having an airless available for your production or painting needs. Additionally, a qualified professional will often diagnose issues that might be overlooked by someone who does not routinely work on airless paint sprayers or have the necessary test equipment. A Professional often times may be able perform the work in a short period of time and depending on how many airless paint sprayers you have may be able to rush work for your company. 2. The length of time you repair work lasts-another factor to consider is how long your airless paint sprayer continues to work after you ve performed a repair. Most airless paint sprayer manufacturers like Graco and Titan will have a suggested number of hours that you should be able to spray without encountering issues. If you are continually rebuilding airless sprayers before for the suggested hours, you may want to consider an outside company

10 to see if there repair services will outlast your repair work in terms of hours of use. Many times a quality repair service will rebuild A pump more thoroughly resulting in longer service times for your equipment. 3. Your familiarity with rebuilding airless paint sprayers-common rebuild needs for airless paint sprayers include repacking the fluid section and if needed replacing the balls and seats. These common tasks are relatively easy to learn and there s a variety of resources online on how to perform these tasks. Even though learning how to rebuild the airless will be easy, most the time it ll take at least one hour but for those who have not done a lot of airless sprayer rebuilding it is more common to take about two hours to properly clean and repair the unit. 4. Guarantee of equipment functionality-a quality airless repair company will stand behind their repair work if they return the unit and it starts malfunctioning in a short period of time they should be willing to ensure that the airless is returned to working order without additional labor fees. 5. The Value of your employee s time- in addition to considering the physical time needed to repair the airless, you should also consider the cost of paying your employee or yourself. To be safe it is usually wise to set aside at least an hour or even two hours labor time to know the cost of labor that will be needed to repair your own airless. In addition to losing time, you also want to consider the potential cost associated with the loss of production. If the employee repairing the airless would otherwise be on the production line or jobsite you want to consider the amount of product or work they would be able to accomplish in the 1 to 2 hour time needed to repair your airless. 6. Are Loaner airless units offered by the repair company-if you only own a single airless and not having it operational will mean an inability to complete a job or manufacture your product some airless repair companies offer loaner units to help ensure you do not lose productivity due to your airless needing repair. 7. Repair parts in stock-if the repair company stocks the parts that will be needed for most common repairs they can often get the unit back to you in a very short period of time or you can also get the repair parts that you need to do the work yourself. Or if you need parts stocked will the repair company work with you to keep needed parts in stock, this can eliminate your downtime whether you choose to repair the unit or the company does it. 8. Pickup services availability-if the airless repair company offers pick up of your nonfunctioning unit you will have no need to remove a worker from production to get the airless unit rebuilt professionally. 9. Safety Airless Paint Sprayers can cause injection injuries and should be worked on with proper safety in mind. You should understand the dangerous of airless sprayers and be able to safely work on them with proper safety equipment. Conclusion By considering these 9 important factors about airless paint sprayer repairs you should be able to make a decision which will help maximize your productivity and keep your ultimate airless repair cost to a minimum.

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12 Pressure pots VS Airless Paint Sprayer s A Complete Guide Airless paint sprayers and pressure pots are popular ways of applying coatings. Both styles of equipment have inherent benefits and drawbacks, which you want to consider before choosing which style equipment you will use for your application. By choosing an appropriate equipment set up, you ll be able to maximize efficiency, finish quality, and production. In this article we will review airless paint sprayer s and pressure pots that you can best decide which one may be right for your coating applications needs. An Overview of Pressure Pots Pressure pots use compressed air to feed a pressure pot which will force feed coating to a spray gun. You can use a pressure pot with an HVLP, conventional, or LVMP spray gun. Each type of spray gun has its benefits and drawbacks as well which you can learn more about here. Pressure pots offer a variety of features as options including multiple regulators, agitation, and even multiple outlets for multiple spray gun s. Additionally, pressure pots can be designed to allow for heating of your coating and for other specialty needs. Compared to an airless paint sprayer, a pressure pot will not supply as high volume of fluid at a given time. However, a pressure pot will allow for finer control of the volume of paint you are supplying a spray gun, the air pressure you are using to atomize a coating, and the pressure that you are supplying a coating at. Depending on the spray gun you use with your pressure pot, you can also save significantly on the amount of coating that you will use. If you can use an HVLP or LVMP spray gun with your pressure pot because your material is not too thick you ll be able to use about half as much paint at a given time compared to using an airless paint sprayer. A fluid line from a pressure pot will also typically require less solvent to clean. If you need further guidance on airless paint sprayers vs HVLP Spray

13 guns and whether an HVLP will work for you check out this guide. Pressure Pot Pros Better control Can use less coating Easier Clean Up Pressure Pot Cons Not as Fast as an Airless An Overview of Airless Paint Sprayers unlike pressure pots that use compressed air to generate fluid pressure, airless paint sprayers use pistons to generate pressure on a fluid which is fed to a small tip that results in atomization of coating. By using a piston to increase fluid pressure airless paint sprayers are able to provide higher pressures than you can achieve with a pressure pot. Additionally, you can supply higher volumes of coating at a time which will allow for higher production compared to a spray gun with a pressure pot. However, you will not have as fine of control over the pressure fluid volume that you are supplying because you do not have independent regulation of fluid and atomization pressure. An additional benefit of an airless paint sprayer is depending on the type of airless you choose, you may not need an air compressor to power the unit. An airless paint sprayer will be less efficient at applying a coating compared to a pressure pot, unless the pressure pot is being used with a conventional spray gun in which case the airless will be similar to the spray gun. Pros of Airless Paint Sprayer Faster Production Cons of Airless Paint Sprayers Less Control Less Efficient than HVLP and LVMP Pressure Fed Spray Guns Ideal Applications for a Pressure Pot with a Spray Gun Applications that require a higher quality finish Applications that require high control over the amount of coating that is applied due to having a precision specification Applications that require keeping VOCs and overspray to a minimum (which would require the use of an HVLP Spray gun ) Ideal Applications for an Airless Paint Sprayer Applications where portability is key for your application Applications where production and speed are the primary concerns for your coating application Applications that you want to Achieve high Film Builds Fast

14 Conclusion By knowing the pros and cons of airless paint sprayers and HVLP pressure fed spray guns you can best determine which may be right for your application. Choosing the right equipment will help you achieve the desired finish and achieve your production goals as well.

15 Latex Paint Spraying Guide Why spray latex with an HVLP spray gun Most of the time when you are spraying latex you will be painting interiors of homes It is often very common to use airless sprayers for this purpose. However, airless sprayers do not provide the same quality of finish that you can achieve with an HVLP Spray Gun. Additionally, an HVLP spray gun is more efficient at applying coating to a product s surface. The downside to an HVLP spray gun is that it will be slower than an airless at finishing a given project. Ultimately, if your main goal is achieving a high quality finish an HVLP spray gun is what you ll most likely want to use. Challenges of using HVLP spray gun with latex paint HVLP spray guns use a high volume of air at low pressure to atomize (break up) coating. The low pressure allows them to use less paint and be more efficient at applying a coating to a product surface. However, the low pressure that HLP spray gun uses can make it harder to break up thicker coatings, including latex paints. To be able to effectively spray latex paint with an HVLP spray gun, a few things will need to be considered. 1. You will need to use a high volume air cap (high CFM) - high quality HVLP spray guns will come with a variety of setups for the air cap as well as the fluid nozzle. The higher the volume of air and air cap uses, the better it will be at being able to atomize heavier bodied coatings like latex paint. 2. If you will be using a turbine driven HVLP spray gun you will want to use a multistage turbine. The more stages that you can afford for your turbine unit, the greater ability the unit will have in being able to spray latex paint. If you are considering between an HVLP spray gun

16 and a turbine unit for latex painting projects, you can learn about the differences between the two here. 3. Use a large fluid nozzle- For a pressure fed HVLP Spray Gun you will usually want to use at least a 1.8 MM Fluid Nozzle. For a Gravity Fed HVLP Spray Gun you will typically need at least a 2.0 or higher to be able to get the Latex Paint to flow. The large fluid nozzle will allow for the latex paint to flow, smaller fluid nozzles will typically be hard to get Latex paint to flow adequately. 4. Thinning-you ll most likely have to thin the latex paint to be able to get it to adequately atomize. This is especially true if your using a gravity fed HVLP Spray gun. You want to make sure to use the manufacturer s recommended thinner and only thin it the minimal amount needed to get it to adequately spray. 5. If you do not want to use thinner, you ll want to consider using a pressure fed HVLP spray gun - pressure fed guns are available for HVLP spray guns that are fed by an air compressor. They will allow thicker coatings to be able to be supplied to the gun effectively and give better control of the amount of coating you are supplying at a given time which can help in achieving better atomization despite the heavy bodied latex paint. You can learn more about pressure vs gravity vs suction fed spray guns here. When an HVLP spray gun is ideal for spraying latex paint When your primary goal is achieving a quality finish like when painting cabinets or trim When you have smaller areas to be painted that will not require a large volume of paint to cover the surface When you need to keep Overspray to a Minimum Alternatives to using an HVLP spray gun with latex paint If you want to be able to maintain high production but still achieve a finer finish, you could potentially use an airless paint sprayer with a fine finish tip. A Fine finish tip allows for higher atomization than a standard airless tip though will not yield the same finish that an HVLP spray gun will. Conclusion if you re looking at a project will require a fine finish and requires the application of latex paint and HVLP spray gun may be the ideal solution for you. To achieve the best result possible, you want to use a high volume CFM air cap, thin the material an appropriate amount, consider using a pressure fed system especially if you will be using a compressor fed HVLP spray can, and if you will be using a turbine driven HvLP spray gun you will want to use a multistage system. By following these tips, you will be able to achieve a quality finish with your latex paint project. For options on compressed air spray guns that might be ideal for your project you can contact us today

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18 HVLP Versus Airless Paint Sprayer A Guide What is an HVLP Spray Gun and How does it work An HVLP spray gun has two separate chambers one for air and one for fluid. Fluid is fed to it fluid nozzle and air is an injected into the fluid after it leaves the nozzle. Fluid can be fed to the HVLP spray gun by a variety of methods including by gravity, a suction cup, or by pressure pressure pot or pressure cup An HVLP spray gun uses the air to effectively break up a coating. The benefit to using air is that it provides a very fine breakup resulting in a high quality finish. Additionally, in HV LP spray gun uses low pressure air and this allows for a very high transfer efficiency of the spray gun. Transfer efficiency references how much of a coating is applied to a product surface versus how much ends up not being applied and becoming overspray. While HVLP uses Low Pressure it does require a High Volume of Air which means it needs a compressor that supports a large CFM of air to be able to feed the spray gun or you will have to use a turbine HVLP Spray Gun unit which you can learn more about here. What is an Airless Paint Sprayer? An airless paint sprayer uses fluid pressure and a small opening to cause fluid to be atomized. Unlike an HVLP spray gun, and airless paint sprayer does not use air to help break apart a coating. Since air is not used in atomizing the coating, and airless paint sprayer will not provide the same finish quality that a HVLP spray gun will. However, since an airless paint sprayer uses a piston pump it will most often provide a higher volume paint then an HVLP spray gun. Additionally, Airless Paint Sprayers are offered in both electric and gas driven models which can help when portability is critical.

19 When is an HVLP Spray Gun the Right Option An HVLP spray gun will typically be best when your primary goal is quality finish that you are applying rather than the speed at which you are applying a coating. An HVLP spray gun also be ideal when you want to minimize the amount of coating that you use, this can be important because it can be a requirement depending on the industry in which you are working as well as the state which you work in, you can find out more by contacting your state EPA.. Another scenario where in HVLP spray gun will be ideal is when you do not need a large volume of paint for your particular product or project. If you only need is a small amount of paint, you can use a gravity fed, suction cup fed, or small two quart pressure cup which will keep your waste to a minimum and keep your coating costs down. To learn more about each method of feeding a spray gun you can review this resource. If your coatings are highly viscous (thick) an HVLP spray gun will not be a good option for your coding application need. This is because in HVLP spray gun is limited in its ability to atomize heavy coatings. When is an Airless Outfit the Right Option An airless paint sprayer will provide higher production and higher pressure. The higher production and higher pressure that an airless provides, makes it an ideal scenario for covering large areas with paint where finish quality is not a huge concern. Additionally, if you have to provide fluid over very long distances because you ll be painting at high heights were far away from your paint equipment an airless will allow paint to be fed effectively. The high pressure that an airless provides, makes it ideal for highly viscous coatings like zinc based coatings, latex, epoxies, and roof coatings. The downside to airless is that it is only about half as efficient at applying a coating to a surface compared to an HVLP spray gun. Ideal Airless Applications Painting large areas like bridges, steel, and new construction Applying thick coatings Painting Ships Painting Locomotives Residential painting with latex Construction work in the Field HVLP Spray Gun Ideal Applications Car repair Car Finishing Wood Surface Coating Application Fine finishes Industries that require HVLP for Emissions Reduction Touch up repair work Conclusion By choosing the right application equipment you can ensure a smooth painting experience. By choosing the proper equipment based on the

20 viscosity of coatings you will spray, the production you need to achieve, and the environment you will be spraying in. If you need additional insight you can download our complete guide to painting equipment here.

21 HVLP Spray Gun FAQ's HVLP Spray Gun FAQ's (Frequently Asked Questions) If you need a complete training on spray application you can download the guide here How Do HVLP Spray Guns Work? HVLP Spray Guns have different paths that material and air travel through. When material leaves the fluid nozzle air is injected into the material by an Air Cap which then breaks up the material that is being sprayed. HVLP spray Guns use a High Volume of Air at a Low Pressure to Effectively Break apart the coating. Why Use a HVLP Spray Gun? An HVLP Spray Gun will have a greater transfer efficiency than most forms of spraying coating including airless and conventional spray guns. For an overview of what is meant by transfer efficiency you can review this article here. How is an HVLP Spray Gun different than a Conventional Spray Gun An HVLP Spray Gun requires a higher volume of air than a conventional spray gun. Volume of air refers to the Cubic feet of air that a spray gun uses when being used. All industrial compressors provide similar pressures of air but have varying amounts of air volume that they will provide. An HVLP Spray Gun will therefore typically require a larger compressor though there are a few HVLP Spray Guns that can work with smaller compressors (they usually will be limited though on coatings that they can effectively atomize more so than HVLP s using Higher air volumes (CFM). Is HVLP required in All Industries and States? No it is not required in all industries federally spray gun requirements are based on industries and are set by the EPA. The EPA has a great site with a lot of sources on emissions regulations including spray guns here. Additionally there could be local or state based rules that will require your particular painting to need HVLP, this is something you can

22 check with the state office for your EPA and they should be able to guide you to a proper local contact. How much Pressure Should I Use? With HVLP spray guns there is typically a maximum pressure listed on the air cap which allows the gun to maintain HVLP efficiency. The air pressure into the HVLP Spray Gun should be at most the pressure that is listed on the air cap. The less pressure you can use while still achieving a satisfactory finish will help in maximizing your transfer efficiency which will help in keeping your costs down. Are There Different Types of HVLP Spray Guns Yes there are two ways which air is supplied to an HVLP Spray Gun and three ways which fluid can be fed to an HVLP Spray Gun. Air Can be fed to an HVLP Spray Gun via a turbine unit which uses a series of fans to provide high volumes of air at low pressure to the spray gun. It can also be fed by a traditional air compressor. For an overview of Turbine vs Compressor HVLP Spray Guns here is a good article. In addition to how air is supplied to the spray gun there three primary ways to feed fluid to your spray gun via pressure, gravity or suction. Each has their benefits and drawbacks which you can learn more about Will HVLP Spray Guns work with my Coating? - HVLP Spray Guns work with a broad variety of coatings including stains, sealers, topcoats, enamels, latex s, and more. The best way to know if an HVLP Spray Gun will work with your coating is to consult your Coatings Technical Data Sheet to see if HVLP is a recommended application method. Why is my HVLP Spray Gun not working right? Common problems with HVLP Spray Guns include they are spitting, the coating is not atomizing properly, or you are getting too much/ too little fluid. You can also review common HVLP Spray Gun Problems and their solution How big of an Air Compressor will I need? An HVLP Spray Gun uses a lot of air and the more you have the better. However, you will typically always need at least 8 CFM for the lowest consuming air volume HVLP Spray Gun, we recommend a minimum of 30 CFM to prevent issues with the gun not atomizing well and changes in the fan pattern occurring. You can learn more about air compressors for spray guns here. How Can I Improve the Longevity of my Spray Gun The best ways to keep your spray gun working well are to ensure you properly clean it and use proper sized fluid nozzles and needles. Additionally, if you are using certain highly abrasive materials like Carc it might be a good idea to consider hardened metal components. If you have to turn your fluid needle in to spray you may want to consider changing to a smaller fluid nozzle as keeping the fluid needle turned in reduces the life of your fluid nozzle and needle. You can read more tips about improving your spray guns life here Why are HVLP Spray Guns different prices HVLP Spray Guns vary in price based on the variety of coatings they will be able to spray, the set ups they offer, how replaceable parts are, and other factors. We have a complete guide on the differences in spray guns and why they exist.

23 Can you Spray Waterborne Coatings with HVLP Spray Guns? You can spray waterborne coatings as long as What size fluid nozzle should I use? A basic rule is the larger the fluid nozzle is the greater volume of paint it will provide. Here is a useful guide on fluid nozzle sizes and choosing the right one for you. Should I lubricate my HVLP Spray Gun You should lubricate parts of your HVLP Spray Gun. The key is to use an appropriate lubricant that is non petroleum and non-silicone based. Why do I get Coarse Texture when Spraying Coarse texture is typically the result of having too much air press and too little fluid pressure Why Do I Get Runs and Sags Runs and Sages are usually the result of too much fluid and not enough air. This could be due to having your pressure pot turned up to high or having to large of a fluid nozzle. Why Do I Keep Getting Orange Peel Orange peel is typically due to not having enough atomization air. If you can increase your air pressure without going above the air pressure that is recommended for the HVLP gun go ahead or you may have to try to thin your paint or consider a different spray method. You can review a complete list of other common finish quality problems and there causes here. Conclusion By considering these questions, you should be closer to knowing whether an HVLP Spray Gun will work well for your application needs. If your setting up your paint equipment for the first time consider download our free slideshow that covers the most important topics about painting for free here. Further Resources Devilbiss HVLP Spray Gun FAQ Binks HVLP Spray Gun Questions

24 Is Powder Coating More Durable Than Paint - A Guide A lot of times customers will be evaluating whether they should be powder or liquid coating for their particular project s needs. Both powder and liquid coating have positives and negatives about them. One of the most frequent reasons the customers consider powder coating over liquid coating is the durability that it provides. Is Powder Coating More Durable Than Paint The short answer the question is that yes powder coating is more durable than liquid coating. The reason powder coating is more durable, is due to two primary facts. First, powder coating applied in a very thick film which provides significant protection against oxidation and damage. Second powder coating is applied at high temperatures which can create a harder cure in the coating helping to add additional protection. However, even though powder coating is more durable there are drawbacks to its use which must be properly evaluated to determine if it is right for your product finish needs. What are the drawbacks of powder coating? Powder coating is applied in thick mil builds the thick mil builds that powder coating is applied in can mean a finish that may not have quite the fine appearance of a liquid coating finish Powder coating requires a higher initial expense-to be able to effectively powder coat you need more equipment than you do when liquid coating. Equipment that you need includes a batch oven for curing the product, a powder coating booth (recovery or non recovery), and a powder coating application gun. Comparatively, liquid coating requires a spray gun and spray booth which are typically much more affordable then the powder coating equipment mentioned above. Powder coating does not allow for easy touchup work-since powder is applied electrostatically and when cured often forms a thick smooth surface, it cannot be easily touched up if the surface is damaged. It is possible to re powder coat the product or touch up with liquid paint but not with the same results that you can achieve touching up a liquid paint finish. Not suitable for all substrates-to be able to use the powder coating, your product must be able to tolerate a relatively high temperature of at least 250 as most powder coatings are cured at 250 degrees or higher.

25 What are the benefits of powder coating? Durability of finish-without a doubt powder coating is significantly superior at resisting the effects of weather as well abrasion. Potentially lower coating costs - depending on the style of powder coating booth you choose and the number of colors you use in production, you can reuse powder and therefore not waste hardly any powder. Unlike liquid coating, which in the best cases you still waste approximately 10% of your paint. Additionally, powder as a product is often cheaper than liquid paints. Pollutes less since powder. Is not expelled through an exhaust duct, it creates very little VOCs. This can be important especially in higher production facilities that would potentially need to use water bourn coatings or invest in equipment to help keep VOC s to an acceptable level. Common powder coating applications patio furniture construction equipment appliances motorcycle and automobile parts Gym equipment Conclusion To sum it all up, powder coating does provide a more durable finish than liquid coating. However, it is not easy to spot repair damage that may occur to the finish, the initial expense of starting up a powder coating process is often higher, and there can be substrate limitations. If durability, lower variable cost, and environmental emissions are key focus areas and your substrate is well suited for powder coating it might be the perfect solution or your coating needs. Have additional questions contact us for a free consultation.

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27 Distance You Should Hold A Spray Gun from a Product, A Complete Guide (Infographic) Why the Distance from the Product you hold a spray gun matters When you are spraying a coating one of the key factors you can control to help achieve the ideal finish is the distance you hold the spray gun from the products surface. Other important variables include the positioning of your spray gun over the wood, the speed at which you move the spray gun, and the settings of the spray gun. Holding the spray gun to close to the surface can result in runs in your paint finish while holding the spray gun to far away can result in uneven coats of paint being applied to your products surface. How Far Away Should You Hold A Spray Gun from a Product Surface? The distance you hold the spray gun from the product will depend somewhat on the equipment you are using. For an airless paint sprayer, you will use the gun at a greater distance from the product s surface as it sprays a lot more paint at a time at higher fluid pressures than an air spray gun. The extra pressure and paint that is released results in faster coverage which means you should hold the gun farther from the products surface to reduce the chance of runs. A good rule of thumb for an airless spray gun is to hold the gun about inches from the products surface. Air Assist Airless Sprayers use high fluid pressure but not as high as

28 Airless paint sprayers. A good rule of thumb for air assist airless sprayers is to hold the spray gun about inches from the products surface Air Spray Guns come in a few styles but the most common are HVLP and Conventional Spray Guns which you can learn more about each here. Each type of spray gun has a different distance that is best to hold it from the products surface. For an HVLP Spray Gun you should typically hold the spray gun 6 8 inches from the products surface. For a conventional spray gun, a bit of a greater distance like 8 10 inches is typically better. How You can know if Your Holding the Spray Gun Too Close or Too Far from the Product Surface Typically holding a spray gun to close to the product while painting will result in too much paint being applied which will cause the paint to run. If you are holding the spray gun to far away from the products surface, you can get a spray that is dusty or sandpaper like Another important consideration about the distance you hold a spray gun When you are painting the spray gun should be moving back and forth and not moving side to side (see picture below for better understanding) Conclusion Holding your spray gun the correct distance from a products surface will help you achieve a proper finish. Other important factors to control include the way you move the spray gun, the spray gun settings, and keeping a uniform technique throughout your painting.

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30 How often To Change Paint Booth Filters - A Guide Why Paint Booth Filters Matter Paint booth filters help collect over spray which refers to coating that has not been applied to your products surface. By efficiently collecting over spray, your paint booth filter provides a few benefits. 1.They protect your paint booths fan from over spray build up. 2. They prevent excessive overs spray from escaping your paint booth's exhaust chamber resulting in coating potentially ruining vehicles or other objects outside of the paint booth's exhaust. 3. A proper paint booth filter that meets all requirements set by the EPA will ensure you are meeting proper regulation requirements (which primarily means the filter meets a minimum efficiency of capturing over spray). 4. By properly maintaining your paint booth filters you can help maintain a cleaner painting environment which can help in achieving a quality finish. How Often To Change Your Paint Booth Filters There are two ways you can determine if your paint booth filters should be changed. One way is primarily visual and the other is via a visual gauge. To visually monitor your paint booth filters you can often base the need for change on any changes in visibility you may see in your paint booth. If you start seeing the air in the paint booth appear as if over spray is in it usually you will want to consider changing paint booth filters. If your filters are relatively new it might be the paint booth itself needs to be checked. In addition to the visual method you can also use a visual gauge called a manometer. When using a manometer you want

31 to make sure you install it appropriately and perform the initial calibration correctly. For an idea of how to install and calibrate a paint booth manometer you can check out this guide. Once you have performed the initial calibration which you do by installing clean filters in the paint booth. Assuring the manometer is set at 0 when the paint booth is on. Turning the paint booth on and marking a line where the gauge oil measures on the manometer. This gives you a clean benchmark which means the resistance your filters provide when they are brand new. From the clean bench mark you will typically place a mark anywhere from 0.25 to 0.5 of water column higher on the gauge this is often based on recommendations from your filter provider as well as OSHA and the EPA in your state. When the filters become filled with over spray the manometer reading will rise and you should change paint booth filters at that time (or if the air seems to be lazy prior to the manometers change out point is reached). Conclusion By routinely and properly changing your paint booth filters you can help maximize the life of your paint booth, reduce over spray from going into the atmosphere, meet proper regulations, and ensure quality finishes for your paint process. To know when to change the filters using both a visual gauge and your overall monitoring of your paint booths condition can ensure you change your filters at an appropriate interval.

32 How to Fix a Dripping or Leaking Spray Gun A spray gun will often leak due to a few different events. First is that the spray gun has been used for a long time and has never had any need for repairs. A second common trigger for a leaking spray gun is that you have just finished rebuilding your spray gun and all of a sudden after replacing everything the gun is shooting fluid around the nozzle or not stopping the flow of fluid when you release the trigger. In the end both events cause the spray gun to not be able to be used correctly which is the real reason why you will want to fix the leaking or dripping spray gun. Why Fluid Leaks or Drips from the Spray Gun To best understand the solution to the problem it is always good to understand the cause. A spray gun relies on seats that are created by tight seals that form between various components in the spray gun. When it comes to fluid flowing in your spray gun, the two most important seats are the seat that is formed between the fluid needle and fluid nozzle and the seat formed between the spray gun's head and fluid nozzle. If these seats stop working or are negatively

33 impacted fluid will leak from your spray gun. Whether it is a drip or a full leak is mostly related to the degree of failure and location of the seat that is failing. How to Fix A Dripping or Leaking Spray Gun If the spray gun is dripping just after you have finished painting this is most commonly caused due to wear or damage of your fluid nozzle and fluid needle. You can start by inspecting the fluid needle to see if their is any obvious deformation to the needle. If there is you may only need to replace the fluid needle, though it is usually better to replace both parts at the same time. If the needle doesn't appear damaged it is most likely that the nozzle and needle have worn and it is time to replace them both. A final source of the problem might be that paint has built up on the fluid needle or nozzle which is preventing the seat from properly forming between the nozzle and needle. If this is the case use an appropriate cleaner to fix the problem. Spray Gun is Leaking a lot of fluid from the fluid nozzle If the spray gun is leaking a continuous stream from the fluid nozzle this is most commonly caused by a lose fluid nozzle. To fix the loose fluid nozzle it is recommended to place the spray gun with a clothe around the handle in a vice. With the spray gun in the vice you will then tighten the nozzle with an appropriate wrench. If tightening the fluid nozzle doesn't resolve the issue there could be a few additional issues causing the problem. You will want to verify the number on the fluid needle. Certain spray guns, for example a Binks 2100 Spray Gun have different needles that are suited for different nozzles. If you have the wrong needle for the fluid nozzle your using a large leak could occur. Paint has stopped the needle from seating - If paint builds up on the needle of your spray gun it can interrupt the seat of the fluid nozzle and needle. By cleaning the needle and nozzle you can fix this issue. Your packing nut could be to tight - If you over tighten the packing nut on your spray gun it will compress the packing preventing the needle from sliding which will prevent it from seating in the fluid nozzle to stop the flow of paint. Your Fluid Needle Needs Lubrication - If your fluid needle is not properly lubricated it may not move freely through the packings which could prevent the needle from seating in the nozzle. The solution is to use an appropriate spray gun lube like Binks Gunners Mate Spray Gun Lube. This lube will not adversely effect your paint finish quality and will allow for the needle to move easily and seat appropriately in the packings. Conclusion Drips or leaks from your spray gun can be problematic. By understanding why leaks happen with spray guns and how to fix them

34 you can ensure that you achieve a good finish repeatedly. If you need further help or want to talk about having your gun repaired we can help contact us today.

35 A Guide to Powder Coating Over an Existing Coating The very short answer is that yes you can often times apply powder coating over an existing paint. However, prior to doing so there are a lot of important factors to consider. In this article we will cover why you may want to powder coat without removing an existing coating, what you need to consider before powder coating over an existing coating, and how you can powder coat over the existing coating. Why You Want to Powder Coat over an Existing Coating One of the greatest benefits to powder coating is its durability as a finish which is one reason why you may want to powder coat over an existing coating. A second reason you may want to not remove the existing coating is that you want to achieve a durable finish with as little added cost as possible. Both of these reasons are good reasons to consider powder coating over an existing coating. However, before choosing powder coating you have to consider the benefits to powder coating, the drawbacks to powder coating, and the potential drawbacks of powder coating without removing the existing coating. To better understand the benefits and drawbacks to powder coating as a process you can read this guide here. What you Need to Consider before Powder Coating Over an Existing Coating To be able to apply a powder coating over an existing coating the underlying coating has to be able to tolerate high temperatures Typically powder coatings are cured at degrees Fahrenheit and so the underlying coating and part itself must be able to tolerate a high temperature so that the powder can be cured You are looking to completely recoat the product Due to the way powder coating works you are not really able to touch up spots on the product but rather will need to recoat the entire product to use powder coating as a method You are ok with a thick film build Powder coating will typically have a minimum of a 2 mil build but for performance it is more common to have a 6 10 mil build on the products surface There is no surface rust breaking through the underlying coating Similar to liquid coatings, powder coating should be applied to a rust free substrate. The paint finish is in good shape The paint applied to the product needs to be free from bare spots in the surface and exhibit good

36 adhesion if the paint is chipping or bare spots are prevalent you should not powder coat over the coating. The underlying coating is not excessively thick If the existing coating is more than 3 4 mils thick you may have trouble getting the product to be grounded to effectively use a powder coating gun because it relies on electrostatic principals to apply powder to the product s surface, you may have to create a bare metal point on the part to be able to ground the part. You May Not Get the Same Durability of Finish Compared to Stripping or sandblasting the Product -Much like applying a liquid coating the quality of your surface preparation will determine to a large degree the adhesion of your coating which also determines the durability of the coating. If you do not remove all the coating and create a surface profile on the product but rather create a profile over the existing coating your powder coat may not last as long as you will be more dependent on the bond formed between the original coating and the product surface. A powder Manufacturer may not guarantee adhesion specs If you coat over an existing coating the powder coating manufacturer may not stand behind the performance of their powder, this will be something to check with the powder manufacturer prior to coating over an existing coating. How you Can Powder Coat over an Existing Coating Step 1 The first step to powder coat over an existing coating is to visually check the coating to make sure the underlying coating does not have bare patches, issues with significant peeling off, or rust break through Step 2- If these issues are not present you should roughen the surface through sanding. If they are present you will need to prep the surface by stripping the old coating. Step 3 Clean the product surface As with any coating application you should clean the surface with an appropriate cleaner to ensure there is no dirt or other surface contaminants present prior to applying the new powder coating. Step 4- Select the proper settings with your powder coating equipment To apply powder over an existing paint you will often have to adjust the setting on the powder coating equipment (commonly using a lower KV setting than the typical KV setting used on a new product surface). Often times the powder gun will have a rework settings selector or if not KV settings between KV s should be used. Additionally, you may have to increase the amount of powder you are using because you need to ensure the surface is thoroughly covered with powder coating so that you do not get a poor appearing finish. Step 5 Cure the powder using the manufacturers recommended cure schedule

37 Conclusion While it is possible to powder coat over an existing coating for best results it is usually better to strip any existing coating off the product surface prior to applying an additional coating. If you are frequently recoating products and want to evaluate issues with your painting process contact us today for a free evaluation.

38 Can you Powder Coat in a Liquid Paint Booth Why Customers want to Powder Coat in a Liquid Paint Booth Occasionally customers want to know whether you can do powder coating in a liquid paint booth. There are two common reasons customers ask about this being possible. First is that the customer has a liquid paint booth but is starting to have needs for powder coating. The second situation is when they are considering a new paint process and looking to save money by keeping equipment investment costs to the minimum needed to effectively meet their paint process needs. The short answer is that you can powder coat in a liquid paint booth, however there are a few variables to consider before powder coating in a liquid paint booth. Things to Consider about Powder Coating in a Liquid Paint Paint Booth Booth Cleanliness Challenges Powder coating is a messy process due to the coating being in powder form - If you require a clean paint booth so that your liquid finishing can have a high quality finish or you need a clean booth environment due to your coating application specification you may not want to use your liquid paint booth for powder coating.

39 You Need a Way to Cure the Powder Coating Powder coating is initially applied using a powder coating outfit that uses differences in electric charges to have the coating adhere to the products surface. After the powder is loosely bound to the surface the product must be cured in elevated temperature to cause the powder to flow into a uniform finish. Powder curing typically requires higher temperatures than most paint booths can provide. Powder coatings typically require atleast 200 degrees but usually even higher temperatures to cure. A typical cure temperature that a paint booth will use is a maximum of 160 degrees. So while you can apply powder in a liquid paint booth you will typically need a batch or infrared oven to cure the powder coating, the benefits of each type of oven are discussed in this article. You will not Be Able to Recover Your Powder Coating while If you plan on higher production in your powder coating operation you will often times want to recover your powder coating, as the ability to recover powder coatings is one of the greatest benefits of powder coating compared to liquid coating which you can read more about Powder Coatings Pros and Cons here. If you convert your liquid paint booth to a powder coating booth you will spray the powder into a modified filter rack which will collect the excess powder and depending on the modification made may allow for air to be recirculated into your shop. To allow for air to be recirculated a permanent change to your paint booth would be required with appropriates changes to the booth including air flow changes and other factors which you should consult with a paint booth provider like us or Global Finishing Solutions to determine if it is feasible. When you are finished powder coating the powder left over will be wasted. You will reduce your overall production ability Changing between powder and liquid finishing will require changing out equipment and properly cleaning equipment for storage. Additionally since powder coating uses electrostatic application equipment you will have additional steps that are needed to prep the booth to coat your product. If you use liquid as well as Powder Coatings in the Same Booth You will Use Filters Rapidly If you combine liquid and powder coating in the same paint booth and using filters to collect over spray the powder and liquid combining together will often result in the filters having a shorter useful life which will cause increased coating costs as well as reduced production due to needing frequent filter changes. How You Can Powder Coat in a Spray Booth If after considering all the potential concerns about converting a liquid paint booth to accommodate powder coating, you will need to consider

40 the following to be able to convert your paint booth to a powder coating capable paint booth. Paint Booth Filtration Modifications - You will most likely need to change to a multi stage paint booth filter so that the powder coating can be effectively captured prior to going out of the paint booth's exhaust stack. Conclusion By considering all the variables that relate to implementing powder coating in a liquid finish booth you can decide if the benefits outweigh the drawbacks. In general it is not recommended to powder and liquid coat in the same booth unless for small quantities. However, if you have questions about implementing powder coating in your production process or implementing powder coating in a liquid paint booth contact us today.

41 Paint Pressure Pot Problems - Causes and Solutions A pressure pot is relatively simple; it is a heavy duty tank that can handle high pressure. On top of the pot there can be a variety of add - ons including multiple regulators for control of fluid and air pressure, agitation to ensure your coating remains in suspension, and in certain situations heat for around the pressure pot to help keep material flowing well inside the pressure pot. While they are relatively simple, there can be a variety of problems that can occur, which can be problematic if you use a pressure pot for the majority of your coating delivery needs. This article will cover the most common problems that occur with paint pressure pots, how they occur, how to reduce their occurrence, and how to fix the issues when they occur. My pressure pot is whistling A common issue that people will experience with their pressure pot is that it will begin making a whistling noise as pressure is increased on the pressure pot. This can be a frightening noise. The cause of this problem is that air is escaping from the top of the lid, which under normal circumstances should not occur. This is caused by a few different issues, by checking these issues you can see what might be causing your pressure pot to whistle. Lid is not tightened enough on all sides most pressure pots will come with a few collars that will allow the lid to be tightened. If the lid is not tightened enough or evenly on each side air will be able to escape from between the lid and pressure pot resulting in a whistling sound. The seal under the lid is worn A pressure pot will typically have a seal that prevents air from escaping from the pressure pot by creating a tight fit between the lid and the pressure pot. If you tried tightening the bolts on each side of the pressure pot and it is still whistling, then the most likely cause is the seal under your pressure pots lid has worn too much and needs replaced. My Regulators Will Not Work To Adjust Air or Fluid Pressures If you are trying to adjust the inlet pressure that your regulators are providing whether it be for fluid or air pressure and they are not adjusting it is usually because the regulators have become damaged.

42 The most common issue that occurs within the regulators is that the internal diaphragms have worn or material has gotten inside the regulator preventing it from adjusting appropriately. This is how you can prevent your fluid and air regulators from wearing prematurely. Do not leave the regulators turned in if you are disconnecting air to the pot. Abrupt removal of the air to the pressure pot can cause a vacuum which can cause material to be pulled up through the regulators which will cause them to not work. If you do not want to have to turn the regulators out routinely you can also add a ball valve prior to the regulators. When you want to disconnect your pressure pots air you would slowly close the ball valve and then remove the air to the pressure pot. This will eliminate the suction being pulled on the pressure pot and improve the life of your regulator. If your regulators are not working you typically will need to Order a Regulator Repair kit for the regulators. Coating Will not move through my Pressure Pot and Spray Gun If you have your pressure applied to the pressure pot and you are not seeing any fluid come out of your pressure pot it could be due to a few reasons. First check to see if coating has hardened in your pressure pot s fluid outlet or if coating has hardened in your pressure pot s fluid line or spray guns fluid passages. If coating has not hardened in your fluid line or fluid outlet you may need to increase the pressure on the pot. If pressure is above 20 pounds or is excessively high and coating is still not flowing you may want to try a larger fluid nozzle or fluid line on your spray gun (unless there is a large height difference between the pot and your spray gun then the pressure may be needed). How to prevent Issues with coating flowing in your pressure pot Review your coatings technical data sheet In a coatings technical data sheet it will often have recommendations on sizes of fluid nozzles as well as equipment that is best suited for your particular application. If your fluid nozzle is too small you will need extra pressure on the pressure pot to paint which will cause your equipment to wear quicker or not be able to spray (this is why we recommend a larger fluid nozzle if it will work for you). If the Technical Data Sheet doesn t specifically mention spray gun application and you cannot get the coating to flow you may need to use different application equipment like a transfer pump with a high pressure ratio or an airless paint sprayer. Properly clean your pressure pot When you are finished spraying you should empty the pressure pot of all coating and afterwards flush the fluid lines with an appropriate solvent until the material leaving the line is clear, by doing this you will reduce the chance that coating will build up in the pressure pots fluid outlet and fluid line. Additionally, once a pressure pot has been flushed you should leave the lid on so that air is not able to enter the fluid lines which could cause any residual coating to harden.

43 Overall if you follow these preventive steps you should be able to use your pressure pot for a very long time without needing to replace any parts of the pot. If you are frequently running into issues with the gauges, wearing parts on your spray gun routinely, or replacing fluid line constantly you may need to implement some of the ideas mentioned here to ensure you prevent issues with your pressure pot. Need additional help knowing if a pressure pot is right for you or why you are having problems with your pressure pot? Contact us for a free consultation.

44 Understanding Theoretical Coverage Rate of Coatings Where is the theoretical Coverage Rate of Coatings Found Coating Manufacturers provide theoretical coverage rates of their coating on their technical data sheets. The technical data sheet provides all the pertinent information you need about a coating including how it reacts to heat, how it should be applied, and recommended surface preparation steps. It can help you know a lot about what level of production you can expect as well as ways you may be able to improve your rate of production by adding heat to your paint booth. How is the theoretical Coverage Rate of Coatings Calculated The theoretical coverage rate of coatings is based on a basic mathematical formula. The rate is determined by taking the typical square footage that would be achieved with a 100 percent solids coating (which is equal to 1604 square feet per gallon). Then that number is multiplied by the decimal equivalent of the products solids content (so.75 for a 75% solids coating) and finally you divide the number by the number of mils you want to apply the coating at. Theoretical Coverage Rate (1604*percent solids in decimal form)/ Desired Mil Build (see calculator below)

45 Why the Theoretical Coverage Rate of Coatings Matter The theoretical Coverage rate provides a basis for determining approximately how much coating you will need for a paint job. Additionally if you will be spraying coating or planning a production process involving paint it will help you determine a lot of factors. How it will help determine production rates & Paint Needed for A Paint Process By knowing the theoretical coverage rate of your coating, the size of your product, and the transfer efficiency of your spray equipment (which you can learn more about transfer efficiency and its meaning here) you can better decide a fluid nozzle size that you may wish to use to meet a production goal. For an overview of the right size fluid nozzle or airless paint sprayer tip to meet a goal of producing so many square feet of product in a given time check out this resource. You can also determine how much coating you will need approximately to spray a given amount of product. Conclusion The theoretical coverage rate of a coating is critical in helping you know the amount of paint you will use in a given project. It also will help you determine the overall costs of coating given a particular project. Finally it can help with determining the potential production rate you can achieve. Cover image courtesy of Aceebee

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47 Refrigerant vs Desiccant Air Dryers Why You Need a Dryer on Your Compressor If you are in the process of purchasing a compressor for your plant, auto body shop, or wood working facility you will want to evaluate the way you remove moisture from your compressed air. Moisture is a natural by product of using an air compressor that when not removed from your compressed air will create a multitude of problems including ruining air tools and causing finish defects in your paint. Two of the most common options to remove moisture from compressed air include a refrigerant dryer or a desiccant dryer. Both units have positives and negatives, the intent of this article is to cover the benefits, drawbacks, and ways each unit works. How a Refrigerant Dryer Works Refrigerant dryers cool the air through a series of steps. Air is first brought into the dryer through a heat exchanger which is partially cooled by the refrigerant air in the system. Air then enters the dryer and is further cooled to 38 degrees Fahrenheit by liquid coolant. The air then exits the dryer through another heat exchanger where it leaves through your piped air. Refrigerant Dryer Pros Affordable - A standard Refrigerant Air Dryer can be sufficient for a large majority of industrial plant applications and if further air purification is needed you can always add an independent desiccant dryer prior to any critical applications (like in a paint booth or prior to a sandblasting application). Effective - A refrigerant dryer will remove most moisture but will not drop the air below the dew point leaving water vapor still present in the compressed air. Not harmed by oil in the air stream - With desiccant dryers you often will need a way to separate oil prior to entering the desiccant dryer so that it doesn't ruin the equipment Options to reduce operating costs - Cooling air requires a lot of electricity. In fact many people do not realize it but compressed air is often one of the largest expenses in your plant. Additionally the refrigerant dryer's can be a high cost. There are two kinds of air dryers on the market today cycling and non cycling. Cycling dryers will cost more at first but less to run (they adjust there use

48 based on the air being produced by the compressor). Non Cycling dryers cost less to buy but will cost more in running costs as they do not adjust their cooling based on the compressors output. Refrigerant Dryer Cons Does not adequately remove moisture for most paint applications and related pertinent applications How a Desiccant Dryer Works A desiccant dryer uses a media called desiccant to adsorb moisture in the compressed air. The systems used shortly after the compressor include regenerate desiccant dryers or single tower deliquescent dryers. The main difference between these two systems is that one can make use of the desiccant multiple times before replacement while the other will require routine maintenance. Within regenerative dryers their are some that use heat and some that don't. Regenerative Desiccant Dryer Pros Able to drop temperature anywhere from -40 to -100 degrees Fahrenheit allowing for removal of almost all vapor.. Lower operating cost due to less replacement of desiccant Regenerative Desiccant Dryer Cons High initial capital expense Must have oil filtered out prior to reaching the regenerative dryer Will have a larger pressure drop Deliquescent Dryer Type Pros Lower initial cost Requires no electricity No moving parts Can be used in hazardous environments Can be installed outdoors Deliquescent Dryer Cons Frequent maintenance of media needed Media could travel in your air pipe creating issues Desiccant must be refilled more regularly Summary If you do not need air with all vapor removed for all your applications a refigerant dryer can be sufficient with the addition of desiccant dryers in important areas of your shop If you need all of your plants air to be suitable for critical applications you will want to evaluate a desiccant dryer for your compressed air. Additional Resources

49 Air Drying Selection

50 EPA Compliant Spray Guns- What You Should Know Spray Guns and EPA Compliance - Why it matters If you are a manufacturer considering implementing a painting process or increasing the amount of paint you do, there are a variety of things to consider. One key aspect is ensuring you meet guidelines specified by the Environmental Protection Agency in relation to the amount of hazardous air pollutants you generate each year from operations. The rules pertinent to hazardous air pollutants are specified on a state and national level. Depending on your state you can often be required to obtain a permit that specifies the amount of your hazardous air pollutants and their source. Depending on the level of emissions you could be required to show plans on how you are controlling or reducing your emissions. If you have a paint process in your manufacturing process and reducing or eliminating your hazardous pollutants is important, then one key area you may need to consider is the spray equipment, paint you are using, and the collection method you are using for over spray. What You Should Know About EPA Compliance The level of Volatile Organic Compounds (VOCS) in your paint along with the paint equipment you are using will be the two primary determinants of the hazardous air pollutants you generate in your painting process. The EPA will look at your coatings first and your equipment second though both are critical to reducing your Hazardous Air Pollutants (HAPS). The standards for HAPs will have both general guidelines and industry specific guidelines. There are a multitude of resources to determine the rules pertinent for your industry. A good point of contact is your state EPA office as their will be state wide and nationwide rules to comply with. You can also find a listing of industry specific national regulations by visiting the EPA s resource here. By checking with these sources you should be able to get the help you need to determine what permits may be required as well as if there are steps you need to take to reduce your emissions. How Can My Paint Contribute to My Hazardous Air Pollutant Levels In short, the higher the VOC content of your coating the higher the

51 level of air pollutants you will generate. When it comes to coating types, as a general rule coatings that are solvent based will have higher VOC contents than an equivalent water borne coating. Additional variables that increase the likely VOC s being emitted include the make up of the coating. Simply put, if you can switch from solvent based to water based coating you will almost always have a reduced level of volatile organic compounds released and in turn a reduced amount of hazardous air pollutants generated. However, there are times when a solvent based coating is needed as they can tend to provide a finish that will last longer. Additionally, certain industries will require the use of a low or NO VOC coating which is why you should check with your industry specific regulations to know what type of coatings are permitted, or if you are running into issues with excessive emissions due to a high volume of production it can often help to evaluate a lower VOC coating. How Can my Spray Gun and Paint Equipment Contribute to my Air Pollutant Levels In addition to the coating your using, the way you apply the coating will impact the amount of hazardous air pollutants you generate. Different types of spray equipment have different degrees of transfer efficiency. Transfer Efficiency is a term that describes the amount of paint or coating that is applied to your product surface vs the amount of paint or coating that bounces or misses your product and is exhausted into your atmosphere. For a general overview of how transfer efficient various categories of spray equipment is you can review this article here. While the transfer efficiency shown in the article may be less than you will achieve in reality because of your product shape and other variables, the EPA will use the manufacturers stated transfer efficiency of equipment to determine the amount of VOC s you are producing. In certain cases, a spray gun must be deemed HVLP compliant which will require a certificate certifying the gun s approval from the EPA. If you want to use a spray gun that is non HVLP but has a similar transfer efficiency you can request approval of your specific equipment by the EPA. What Do Spray Booth Filters Do for EPA Compliance? Ultimately your spray booth filters will not reduce your overall emissions of Volatile Organic Compounds. However, the EPA does have requirements related to paint booth filters efficiency unless you meet certain exceptions which are listed in EPA 40 CFR Part 63. Otherwise you are required to have a filter that is demonstrated by the manufacturer to be 98% efficient at collecting overspray. Conclusion The spray gun you use and the coating you spray will be the two primary factors in the emissions you produce in your painting work. The EPA has national rules and state level workers to help identify pertinent

52 regulations relevant to your manufacturing. Each industry has different requirements related to the acceptable VOC content of your coating and other requirements. By choosing a coating with the lowest VOC s and a spray gun with the highest transfer efficiency you can help reduce the emissions you produce. Links To Spray Gun Compliance Documents Devilbiss EPA Compliance Documents

53 Infrared vs Convection Ovens for Paint Curing When it comes to accelerating product dry time of powder or liquid coated products heat and infrared are the two primary ways to accelerate the dry time of the product. Each method has its benefits and drawbacks and can be right for you depending on your needs. Our goal is uncover the Pros and Cons of Infrared and Convection ovens so you can make a good choice about which might be right for your product needs. Infrared Ovens Pros Lower Energy Consumption - In most situations an infrared oven will be a higher efficiency oven. This is due to the nature of how an infrared oven cures a coating. Infrared ovens utilize infrared waves to accelerate drying of the coating alone. Unlike convection ovens that require the heat to elevate the temperature of the product and the coating to enable the product to cure. The end result of this difference is that an infrared oven will be more energy efficient Potentially Faster Cure Times - Since an infrared oven doesn't require the product surface to be heated before curing of the coating starts and it immediately starts curing the whole thickness of the coating from the start, infrared can be a faster way of curing a coating. Cost savings on operation - since an infrared will typically use less energy it will usually have lower operating costs. Smaller in overall size in comparison to equivalent convection oven Will not elevate product surface temperature - If your product will change shape due to temperature elevation infrared does not elevate the surface temperature of the product which makes it an ideal choice for substrates that are sensitive to temperature elevations like plastics Greater Control over curing - Infrared ovens can change the wavelengths of energy used to alter the rate at which a product is cured. A convection oven on the other hand only has the temperature and movement of air to change the curing process Infrared Oven Cons Infrared ovens require line of sight to cure a product - What this means practically is that infrared ovens will not typically do as well

54 with objects that have a lot of recessed or protruding areas (objects that are significantly different than flat). The infrared oven has to have its infrared waves directly come in contact with the coating surface to be cured. Limitations with Certain Coatings - If a coating is excessively reflective in nature it will sometimes not cure well using Infrared technology. This is because rather than the infrared waves penetrating the coating and curing throughout the coating, it will cure only the top of the coating or will not cure well at all. Slower cure times depending on product surface - With the product surface reflectivity is a good thing because it causes more exposure from a single infrared wave Convection Oven Pros Lower Initial Cost - Typically a convection oven will have a lower initial purchase price over a Infrared Oven. Additionally there are a lot of quality used convection ovens on the market that can be found at a lower price No limitations on Part Shape - Convection ovens do not have any limitations on the shape of the product. Unlike infrared ovens that depend on energy waves to cure the product, Convection ovens heat the entire surrounding air which allows for curing of any recesses in the product surface. Less Coating Limitations - Unlike Infrared Ovens a Convection paint oven will cure a greater variety of coatings. Convection Oven Cons Not Suitable for All Substrates - A convection oven will heat the product surface making it less ideal for products that high temperatures (above 200F) will alter the products surface Potentially Higher operating costs - Due to having to heat the ambient air before curing starts and due to the way heat is generated, Convection ovens have higher running costs. This will usually depend on the prevailing costs of the method heat is generated (electric or natural gas) Higher Maintenance Costs - Larger Floor Space Required - If a convection oven is the same size inside as an infrared oven it will require a larger overall footprint which can be important if shop floor space is at a premium Combination Infrared and Convection Ovens Pros Fastest cure time - By combining infrared and heat elevation you will be able to achieve the fastest cure times Best Curing of High Film Thickness Builds - By utilizing both infrared waves and heat you can cure high film builds most effectively Cons

55 Highest maintenance required - You have to properly maintain both a convection and infrared oven Highest initial cost Alternatives If you want to cure a coating but it doesn't need high temperatures (above 200 degrees) you can incorporate a bake feature into your paint booth. To learn more about baking in a paint booth you can read about it here. Steps to Take An infrared or convection oven is a large expense. To best know whether one is right for you we recommend having your intended product and coating tested in both options to best know which will perform right for you. If you want further assistance evaluating a infrared vs convection based oven let us know and we can help you determine if one is right for your production needs. Summary Infrared ovens are ideal if you have a relatively uniform product surface without recesses and want to minimze operating costs. Infrared ovens are also ideal if you have a product substrate that cannot be heated without changing the product surface. Their can be limitations with certain coatings and surfaces so you should have someone cure your coating and product to make sure it will work for you. Convection ovens will work with the most coatings, work well with surfaces that are uneven, and have less limiations on product substrates. They typically will have higher operating costs than an infrared oven. They are also can be slower in curing than an infrared oven. Further Resources PCI Magazine Convection vs Infrared Ovens

56 Air Assisted Airless Versus HVLP HVLP and AIr Assist Airless share a lot of similar benefits but they also have unique challenges and differences. This article will highlight both the benefits and drawbacks. This will help you decide if Air Assist Airless or HVLP Spray technology is a better solution for your surface coating needs. You can also learn how to convert your Airless Paint Sprayer into an Air Assist Airless here. HVLP HVLP Benefits over Air Assist Airless Finer control of fluid and air delivery - Compared to an air assist airless sprayer a HVLP Spray Gun will allow better control over the amount of fluid and air delivered at a time. This is beneficial when you need high control over coating application due to needing a very thin coating applied. Better control of your fan size - HVLP has a fan pattern adjustment which allows for better control over the fan pattern of your spray gun. As previously mentioned you can also adjust the fluid and air delivery. This allows you to control your spray pattern anywhere from an inch to 15 inches. The benefit is that this will allow you to spray a variety of surfaces with better control and accuracy. Less Coating Waste - Although Air Assist Airless and HVLP have comparable transfer efficiency, an Air Assist Airless will require flushing out of your fluid lines. While a HVLP Spray Gun might have a fluid line, even with the line you can back pressure a HVLP Spray Gun and typically the line will be less length than an Air Assist Airless unit. Requires less Compressed Air (if your using a Air Driven Air Assist Airless) - A HVLP Spray Gun will require about CFM of compressed air. An Air Assist Airless will require typically anywhere from 40 CFM up to 200 CFM depending on the Fluid Delivery Rate. HVLP Spray Guns will provide a slightly better finish quality Air Assist Airless Benefits over HVLP Spray Guns Faster production - Air Assist Airless units will apply coating a lot faster than a HVLP Spray Gun. This can be important where production is your primary goal. Application of Heavier Coatings - Air Assist Airless uses both Pressure and Air to help atomize your coating. Which will allow an air assist airless unit to atomize heavier coatings.

57 Similarities between HVLP and Air Assist Airless Both have great transfer efficiency (approximately 65% transfer efficient Both come in portable options Air Assist Airless comes in electric or gas driven while HVLP Spray Guns come as electric driven turbine setups which you can learn more about electric vs air driven HVLP here. Both provide a quality finish Which one is right for you? If you need greater control and ultimate appearance of your finish being applied consider an HVLP If you need production, or heavier coating application but still want efficiency, production, and quality finish, consider an Air Assist Airless. If you need pure production consider a typical airless. Further Resources

58 How to Use a Wet Film Gauge A wet film gauge is one of the most important tools in coating application work. Being able to use it properly to know the wet film thickness of the coating you applied will allow you to achieve a desired dry film. To calculate the wet film thickness, dry film thickness, and the amount of coating you need to meet a wet film or dry goal based on how you apply it you can check out this calculator it will also help you know the right fluid nozzle or airless tip to use to meet your production goal. Now with your wet film goal in mind we can move on: How to use A Wet Film Gauge If you need any further assistance with applying a coating or need a wet film gauge we can help troubleshoot application challenges.

59 Spray Gun Compressed Air Filter Guide Clean air for your spray guns is critical in achieving the finish you desire. Contamination in you filter air can result in fish eyes, dust in your finish, adhesion problems, poor gloss, and poor coating performance. These issues cost both time and money in your painting and are critical to reduce and eliminate. Fortunately with proper air filtration you can prevent these issues from occurring. Types of Compressed Air Filters for Spray Guns There are a variety of compressed air options for spray guns but they will primarily be in two categories those that filter air near the spray gun and those that filter air at the compressor. Both options have benefits and drawbacks which we will discuss. Within each system you have 3 stages of air filtration. For an overview of the 3 stages of air flitration here is a good article covering the 3 stages of air filtration. The summary of air filtration is that it comes in 3 stages first is an oil water seperator, second is an oil water seperator with a coalescent filter, and the final (most clean air option) is an oil water seperator, coalescent filter, and dessicant dryer (which provides the greatest degree of clean air by taking the air down to a dew point removing all moisture). Filtering air at the Compressor Air can be filtered at the compressor using a refrigerant or desiccant dryer and a oil water separator. This has its pros and cons Pros Cons Will filter all air for your tools - this helps reduce any performance or equipment failure as the air will be clean for all your tools Only need to worry about maintenance for the equipment at the compressor vs needing to be aware of air filters that may be at various air line drops throughout your facility Save on equipment problems due to clean air throughout your plant Expense - a full refrigerant dryer along with an oil water separator for your compressor can be highly expensive. They can easily cost $16,000 or more. Desiccant dryers for compressors can cost more than even a refrigerant dryer If you have minimal air tools it will be a greater expense than is necessary Filtering Air Near the Spray Gun (off an Air Line Drop)

60 Pros Will be less costly - A typical extractor and coalescer filter will cost around $600 dollars. Even a unit with dessicant (the cleanest degree of air you can have) is only around $800. This is significantly more affordable than a extractor and dryer for an entire compressed air system Will maximize the quality of clean air - By having the air filtered immediately prior to the source of the gun you remove any contaminants that might be residual in the plant piping from years of use or wear and tear Cons Doesn't filter air for all equipment which can result in damage to other air driven power tools If after reading this and you need further help with your air filtration to determine what is right for your needs contact us or you can see our air filtration options here. Further resources on Air Compressor Air Filtration Compressed Air Dryer Selection Guide

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62 Choosing a Pressure Pot for Painting A quality spray gun with a pressure pot is one of the most versatile painting tools you can purchase. With the right pot and spray gun you can paint anything from an airplane to small parts. To maximize your productivity and effectiveness it is essential to select a properly sized and set up pressure pot for your painting needs. Choosing a Pressure Pot for Painting; Things to Consider Variable 1 - The number of regulators you want for your pressure pot Depending on the manufacturer, pressure pots will come with a variety of gauge configurations including single or dual regulation. Two regulators provides greater control at the pressure pot but with an additional cost for the second regulator. The second regulator provides control inside of your paint booth rather than requiring the painter to go outside of the booth to change air pressure. This allows for greater production, especially if coatings will change regularly because the painter can make all adjustments in the paint booth. It also provides a bit more accurate control as the air travels a shorter distance to the gun reducing any change in air pressure due to pressure drop. Variable 2 - How fine of control do you need in adjusting your pressure pot Again depending on the manufacturer pressure pots for painting will have the option of standard or sensitive regulators. A sensitive regulator has a smaller range that it will read which allows for greater control of the pressure you are using with your coatings. This is typically important when you have a coating you need applied lightly or with a coating that has a very low viscosity and will flow with minimal fluid pressure (stains are one prime example of this). If fine control is less important standard regulators will be best. Variable 3 - Do You Need Agitation? If your coating needs to be mixed continuously because it is a suspension or otherwise will settle out then you will need agitation. The key is how viscous is your coating (if its a medium to heavy viscosity coating you will need a gear reduced agitator otherwise a direct drive agitator will work). What is a direct drive agitator - A direct drive agitator drives the agitator from the air motor without any reduction of speed What is a Reduced Gear Agitator - A reduced gear agitator takes the

63 shaft of the air motor and connects it to a reducing gear which creates more power and a slower rotation. This is important for heavy bodied material like zincs or epoxies. Variable 4 - Is the coating Highly Viscous? Consider a bottom outlet or adding heat If the coating is extraordinarily thick like zincs and certain high solid epoxies you may need to use a bottom outlet kit, thinner, or water jacket. Each of these methods will allow you to reduce the viscosity of the coating but via different methods. The bottom outlet kit will allow you to leverage gravity to help the coating flow (this is particularly helpful with larger pressure tanks) Thinner will reduce the coating but can create extra thinner use which is a ongoing expense. A water jacket for the pressure pot can increase the temperature of the coating allowing the viscosity to be reduced naturally just make sure that the jacket is designed for use with paint so that no danger arises with heat and solvent. Variable 5 - How Long of a Pot life Does Your Coating Have or how long before it starts hardening Pot life is the amount of time your coating will last before it begins to harden. This is important with a pressure tank because if the coating begins to harden while in your pressure tank it can cause issues with cleaning the tank or even ruin the pressure tank along with the spray gun. Below are recommendations of pot size based on pot life/ hardening time courtesy of Binks. Variable 6 - Volume of Production If you will use the same coating all day you will want to reference the chart above to choose a pressure pot size that will allow for the most painting time before needing to refill. Variable 7 - Frequency of Coating Changes If you will be changing your coatings routinely you will want to consider a smaller pot size based on how often you will change coatings so that you do not waste excessive coating when changing to a new coating. By considering these 7 factors when choosing a pressure pot you can

64 maximize your production while keeping the costs of your pressure pot down.

65 Spray Gun Air Cap Selection Guide Why Air Cap Selection is Important The Air Cap for your Spray Gun is critical because it will be one of two primary factors that determine the finish quality of your painting as well as the speed at which you can paint. The air cap will also determine how thick of coating you can atomize and spray pattern size. To know best which Air Cap is right consider the following. What is the Material Being Sprayed? Different coatings will spray well with different air cap technologies (air caps are available in conventional, LVMP, and HVLP designs. Each style cap has its benefits and drawbacks. Additionally within each category you can use a gun that is fed by suction, gravity, or pressure. To best understand the difference between HVLP, LVMP, and Conventional consider this article which provides an overview. For a review of the benefits and drawbacks of suction and pressured fed spray guns you can check out this overview. Remember you can use a suction feed air cap on a pressure fed spray gun but you cannot use a pressure feed air cap on a suction fed spray gun. The short summary is a pressure fed gun is best for production and/or high viscosity coatings. Gravity fed spray guns are great for smaller batches with light to medium viscosity coatings (like in wood finishing or the auto industry). Suction fed spray guns take the least time to learn and can be a good first spray gun because they allow you to convert them to a pressure fed spray gun which provides versatility (though they will not atomize heavy coatings well) What is the Fluid Nozzle Size? Air caps will come with a variety of CFM ratings. A higher CFM air cap provides a larger ability to atomize and a larger pattern. This means a high CFM air cap is great for high production or heavy viscosity coatings. If you have a large fluid nozzle you will typically want to match it with the highest CFM air cap available for that spray gun to ensure the air cap can keep up with the fluid delivery. If your fluid nozzle is small you can choose between the air caps based on spray pattern. What is your product size? Spray gun air caps from good manufacturers will come with a variety of caps with different pattern sizes. When choosing a paint gun air cap you will want to choose a cap that provides a pattern that is wide but not excessively so essentially you want to have a pattern that will cover the product in the least number of passes but still allow for

66 pattern overlapping during painting. For example if your product is 24 inches in diameter you would want to choose an air cap that will allow a pattern of 12-14". This is because you have to overlap each pass so if you use a 14 inch pattern you can overlap a few inches but still cover the product in 2 passes while minimizing over spray. Additionally if your target is small a round spray pattern can be ideal as it will be significantly smaller than the standard air cap spray pattern. What does the Paint Gun Manufacturer Recommend? Good spray equipment manufacturers like Binks, Devilbiss, Sata, and Iwata will have product sheets that have information about pattern size as well as air cap recommendations for different coating categories. Consider their suggestion along with the information above to yield optimum results. If you need further help finding the right air cap for your painting let us know. Sample Air Cap Selection from Binks Trophy Spray Gun.

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68 A Complete Guide to Keeping a Paint Booth Clean Paint Booths are an investment that can cost anywhere from $1000 dollars to hundreds of thousands of dollars. The beauty of a paint booth is with proper care and maintenance they can last 40 years. This article is a complete guide on how you can maintain a clean, well functioning paint booth. Protect the Paint Booth from Over spray One of the biggest problems within your paint booth is over spray which will have a tendency to build up on the spray booth's walls, lights, and floor over time. To prevent these issues it is recommended to use a peel-able paint booth coating. Paint booth coating provides protection to the underlying sheet metal of your paint booth and is removable, which will prevent the walls of your paint booth becoming overly contaminated over time. In addition to the booth covering you will want to protect your lights from over spray build up so that you do not have issues with visibility due to excessive coating build up. This is done with a mask for the paint booth lights. A final area of preventive care is to utilize floor coverings for your paint booth. A floor covering will prevent build up of over spray on the floor. Protect the Paint Booth Fan from Paint and Maintain it Properly Your paint booth fan is one of the few items in your paint booth that over time could wear out. To help reduce the chances of your paint booth fan wearing out follow these steps. 1. Follow the maintenance program laid out in your manual this will ensure your paint booth fan runs reliably for many years 2. Use a quality paint booth filter. Paint booth filters prevent over spray from landing on cars in your parking lot as well as protect the fan blade from over spray. By using a quality paint booth filter and routinely replacing the filters you can ensure the fan will last a long time. It can be tempting to use low quality filters but they can lead to long term failure of your fan due to over spray buildup 3. Change your paint booth filters routinely. A paint booth should have a visual gauge called a manometer to help know when the filters need changed. If you need to learn more about the manometer and how to use it you can review this article here. The ultimate gauge is if the over spray is hanging in your paint booth's air it is time to change filters or if the manometer is showing the filters are dirty.

69 Maintain your Air Make Up Unit Your manufacturer will have a paint booth air make up guide that will lay out recommended maintenance steps. You can also review a quick overview of air make up care here. Keep the Booth Free From Outside Contaminants The best way to keep the interior of the paint booth free from dust and other contaminants if you have an enclosed booth is to ensure all the gaps are properly caulked to from a seal. What if you are trying to clean a dirty paint booth? While maintenance is always easier than restoring a dirty paint booth you may find yourself in a situation with a dirty paint booth. If you have a paint booth there are a few options. You can use a booth coating that can be applied over a dirty booth wall (while normal booth coating requires bare galvanized metal). You can also use scrapers that are non sparking to clean existing over spray off your paint booth's walls or use solvent solution and a sponge mop NOT A COTTON MOP as it will breakdown. You can avoid having to clean the booth by using a peel-able booth coating that can be applied over dirty paint booth walls. By following these maintenance, cleaning, and care tips you can ensure your paint booth will last a long time and run without issues. Further Resources Global Finishing Spray Booth Cleaning Tips

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71 Choosing an Airless Paint Sprayer Tip (Along with Calculator) The size of your airless paint sprayer's tip will determine the speed at which you can apply coating, it will also determine the thickness of coating you can successfully apply with your airless paint sprayer. With so much being tied to choosing the correct airless tip, it is important to consider the following. How to Read the Airless Paint Sprayers Tip Information The tip of your airless paint sprayer will have 3 numbers at the end of the tip like 515, The first number doubled will give you the approximate size of the spray pattern. The second two numbers provide the size of the tip oepning in thousands (15 thousandiths in this case). The tip pattern assumes you maintain inches of distance between you and the product Size of Your Airless Paint Sprayer Your airless unit has a maximum amount of Gallons per minute of Paint that it will be able to successfully provide for you to paint with. Ideally you want your airless paint sprayer to only run at about 70% of its maximum gallons per minute capacity. This is so that as the tip wears you are not excessively running your airless paint sprayer pump, which can cause frequent breakdown and issues with how the coating sprays The size of your airless tip determines the amount of paint the sprayer will be able to apply at a given time. Once you know your airless GPM review the chart below to ensure the tip size is appropriate for your sprayers capacity. Chart Courtesy of Titan Tool Desired Paint Pattern The pattern of your spray will vary from 2" up to 14". A larger pattern

72 will be able to paint faster but with the potential for additional waste. Ideally you should try to keep the pattern to a size that will allow you to cover the product in as few passes as possible but with the smallest amount of the pattern being larger than the target. For example if your target is 12 inches wide you would want to consider a tip that would allow for a 6-8" pattern. You can use a larger tip size but this would supply excessive coating, which may cause runs or other paint defects. Desired Production Level The speed which you will be able to complete projects will be mostly related to the spray pattern and fluid flow rate which will provide the speed which you can cover a certain target. You can use the calculator below to find the right tip size or consult this link for an additional calculator for determining the fluid flow rate needed. With that number in mind you can select an airless tip to meet your production goal, though it is recommended to try the tip first to see if it is providing to much paint for you to move fast enough to prevent runs or other finish defects. Coating you Are Spraying Different coatings will have different requirements for airless tips. Certain coatings will require a larger tip regardless of the volume of painting being done to being excessively viscous or thick. Your coating should have a technical data sheet that will provide the airless tip sizes the company recommends. However as a general principal heavier bodied coatings (lzincs, epoxies, ) will need a larger opening and

73 thinner coatings (stains, lacquerers) will need a smaller opening. You can often talk to an equipment provider and they can give you a estimate of the proper tip sizes for various coatings. If you need help with picking out a airless paint sprayer tip let us know and we are glad to help.

74 How to Know CFM for a Paint Booth & Exhaust Fan Size Why Paint Booth CFM is Important Paint booths are designed to meet a minimum air flow requirement to be compliant with national codes that govern spray booths. Important codes that paint booths comply with include National Fire Code 1, NFPA 33, OSHA, and a few others. For a good overview of all paint booth code compliance check out this article. The important thing is that to meet code compliance a paint booth is required to exhaust an appropriate amount of air. The amount of air a paint booth exhausts will depend on the style of paint booth. The three main styles of paint booths are cross draft, down draft, and side down draft paint booths. There air flow requirements are summarized below. In the past NFPA dictated paint booth air flow needed to be 100 FPM for non electric static coating application, downdrafts were usually between FPM. Revisions to the code now dictate that the exhaust must be sufficient that solvent concentration is below 25% of the lower flammable limit. To properly measure the solvent concentration requires expensive tools and so most of the time air flow rates will help to know if your booth is running approximately how it should be, to be safe consult with the booth manufacturer to know you have a proper sized paint booth fan replacement in mind. If you do not have proper air flow it is a safety hazard, it can effect the finish quality of your product, and can cause your painters to have trouble working in the paint booth due to visibility problems How to Know about the CFM Your Paint Booth Should Be exhausting Cross Draft Paint Booths For a Crossdraft paint booth the booth should remove approximately

75 100 FPM across the face opening of the paint booth plus any additional openings should be included. SO you take the width and height of the paint booth x 100 FPM and will provide the exhaust speed in Cubit Feet a minute. Lets take two quick examples to best understand the math Crossdraft Paint Booth is 6 feet wide x 8 feet high your air flow will be 6 feet x 8 feet x 100 FPM = 4,800 CFM per minute You have a Crossdraft Paint Booth with a 6 feet by 8 feet opening with a 4 feet by 4 feet crane opening you take the face opening 6 * 8 + (4 *4 ) then take this x 100 = 6,400 CFM Down Draft Paint Booths A Downdraft Paint Booth will remove approximately 50 FPM across the floor print of the paint booth. Lets take the following for an example You have a downdraft paint booth that is 30 feet long x 14 feet wide this means the booth will remove approximately 21,000 CFM (30 x 14 x 50) Side Down Draft Paint Booth Side downdraft paint booths work on the same speeds necessary as downdraft paint booths. However, a side down draft paint booth will often use a few smaller paint booth fans. This makes side downdraft paint booths often require each fan size to know what is a good replacement fan. Special Situations (Exhaust Chambers ) The majority of regular paint booths will have a Totally Enclosed Paint Booth fan. If you are using an exhaust chamber rather than the full spray booth fan it is important to remember that it is most likely not a spray booth, you will want to make sure to coordinate with your local authority to ensure all proper safety processes are in place. Additionally it can be good to consider an explosion proof fan motor as this will reduce the chance of your fan causing a spark. Unlike a regular paint booth their is a little more chance that the fan could be a sparking source. Paint Booth Fan Types & There CFM Totally Enclosed - A totally enclosed fan is the typical tube axial fan that most paint booth utilizes it prevents air from outside of the fan to flow across the motor which reduces the chance that solvent laden air would be ignited by the fan Explosion Proof - An explosion proof fan will have designed features that reduce the risk of a spark forming Variable Pitch Sheave Design - A Variable Pitch Fan allows for adjusting of the fans speed which can allow for adjustment of the fans speed. This is a great option for a fan replacement as it will allow for balancing of an older paint booth by adjusting the air flow. Each fan will have a varying CFM rating and you will want the fan

76 to be rated for an appropriate static resistance based on the length of duct you have, elbows in the duct, and similar factors. If you need help with knowing the right size fan its best to speak to the provider of the booth to ensure it is appropriate.

77 How to Choose A Spray Gun Fluid Nozzle Size Spray Gun Fluid nozzles control the amount of coating you can apply at a given time with your spray gun. They also determine the thickness of coating you can apply without thinning when using a gravity fed spray gun. Essentially choosing the proper fluid nozzle will help to reduce paint waste and ensure you apply the appropriate amount of coating for your product's needs. The goal of this article is to provide a guide on how you can choose the right fluid nozzle for your spray gun How to Find the Right Fluid Nozzle for Your Spray Gun With any technical data sheet that comes with coatings their should be a recommended spray gun fluid nozzle size range. This will help to give a rough estimate of the right fluid nozzle. Typically pressure fed spray guns will use a smaller fluid nozzle than suction (the suction nozzle will be sizes bigger which means the next size up in fluid nozzles With the service manual that comes with most spray guns there will be a chart showing fluid nozzle sizes and which size fluid nozzle and what size air cap is recommended for various coatings If you are not able to keep up with production or having to make numerous passes you should consider the next largest fluid nozzle or if your coating is getting runs in it then consider a smaller fluid nozzle. Calculators to determine the exact size fluid nozzle for your Paint Gun enter highlighted cells information only Calculator 1 is based on percent solids of material if you do not have a technical data sheet available Step 1 Perform a Flow Rate Test if using a spray gun if considering an airless or air assist airless use the chart at the bottom of the article A Flow Rate Test is when you turn off all atomization air to your spray gun and trigger the spray gun while catching the paint being dispensed for 60 seconds. You then should have how many ounces per minute of coating your dispensing. You can use one of the two calculators below. This first calculator is based on percent solids that is in your coating the second is based on square feet of coverage specified in your coatings technical data sheet.

78 1. Measure All Surfaces to be painted in feet and enter in length and width section or use this calculator and determine total square feet to put into box by inputting length and width of all surfaces to be painted (you can use inches in this calculator in addition to feet) 2. Enter Your Coatings Percent Solids in decimal form (remember to adjust percent solids based on any thinner being added consult this chart for info on thinner added and the percent solids that will result) 3. Enter Your Paint Equipment's Transfer Efficiency, you can review transfer efficiency of paint equipment here 4. Enter Dry Film Goal DO NOT ENTER WET FILM IT IS CALCULATED BASED ON PERCENT SOLIDS OF MATERIAL 5. Enter Time you want to complete your product in and you will receive FLUID FLOW RATE 6. Take FLUID FLOW RATE AND FIND APPROPRIATE FLUID NOZZLE or Consider Airless if Higher Production Needed (see chart below to see GPM of nozzles using airless Paint Sprayer) remember if you change to an airless unit or a different type of spray gun (conventional vs HVLP) you will have to recalculate the fluid rate needed because transfer efficiency will be different Calculator 2 uses Square feet of coverage of your coatings from a technical data sheet Enter all highlighted cells using the information from your technical data sheet to determine fluid rate needed. Perform flow test with spray gun to determine proper fluid nozzle size. Doesn't include any added thinner.

79 GPM of Airless Based on Tip Size Airless Tip Size GPM Ounces Per minute Remember just because a given fluid nozzle will provide a certain production rate you will have to test the spraying of the coating to make sure you can achieve your desired finish quality requirements given the fluid nozzle size. Further Resources Devilbiss Fluid Nozzle Selection Guide Tool - Devilbiss provides fluid nozzle recommendations for all the major automotive coating manufacturers for their spray guns. Automotive Tip Size General Guide If you need further help meeting your production needs and fluid nozzle give us a call and will help

80 How Much Does A Paint Booth Cost, A Complete Cost Guide When it comes to paint finishing your paint booth is often your largest expense(unless you are a large manufacturer with a lot of additional paint equipment). If your planning on opening an auto body shop, an industrial coating facility, a fabrication shop, or even a hobbyist shop you will want to consider the cost of your paint booth as you plan your building. This article will cover factors contributing to a paint booths costs and then provide simple rules of thumb to help estimate the price of a paint booth. Factor # 1 - Amount of Air the Paint Booth Exhausts Paint booths have to remove a significant volume of air to be able to meet NFPA 1 and speifically NFPA 33 (which is more specific to paint booths). The amount of air removed by your paint booth will depend on if it is a crossdraft, side downdraft, or downdraft. A crossdraft air requirement is approximately 100 FPM x the face area of the opening of the paint booth, while a downdraft and side downdraft booth requires 50 FPM x the footprint of the paint booth. The higher the CFM of the paint booth the higher the cost for two reasons. One is the paint booth will require a larger exhaust fan to move the appropriate volume of air. Two, you are more likely to need to replace your paint booths air leading to the need for an Air Make Up Unit. Third, a larger paint booth will require larger duct work which will result in additional cost. To keep costs of your paint booth as reasonable as possible try to keep the paint booth size to the smallest face area for a crossdraft or footprint for a downdraft as possible. For an idea of determining an appropriate paint booth size refer to this article for helpful tips. Factor #2 (and typically the largest expense factor) - Will you need An Air Make Up Unit for the Paint Booth? An air make up unit replaces the air being removed from your building. It prevents you from losing all of your facilities heat in the winter and prevents excessive negative air pressure due to having a small facility that your paint booth will be located in. To determine if you may need to consider an air make up unit for your spray booth this article covers what you need to know or you can reference the calculator below to see how fast you will remove all air from your building. Essentially were trying to determine if you will remove all the air from your building in 20 minutes or less which will definitely require considering an air make up, outside of that you will have to determine if a cold paint booth in winter

81 will be problematic for production and long term needs. In general the air make up for a paint booth will be one of the largest expenses often costing as much or more than the paint booth itself. Please input the size of your paint booth and your building and the CFM as well as Time until the Building has all heated or cooled air exhausted will be calculated. Factor #3 - Is the Booth a Factory Standard or Completely Custom? Standard spray booths that are not custom engineered will be a much better cost. Standard spray booths due have size restrictions though and if you have an exact size that you need a custom engineered paint booth can often be necessary. A custom designed paint booth can end up costing quite a bit more than a pre designed paint booth due to the custom manufacturing needed and engineering work. Factor# 4 - How Big is the Paint Booth and what style Paint Booth is it? The size of the paint booth will require varying amounts of sheet metal and if over a certain size additional structural support. Additionally booths typically go in the following order of increasing expense: Crossdraft, Downdraft, Side Downdraft. For a downdraft you have to include an additional cost of concrete work as they have a concrete pit in the floor. For a side downdraft you have an additional cost of double the fans and double duct runs of a crossdraft paint booth. For a general range of prices consider the following for a guide, this is without duct work included (which is the 5th factor) and not including an air make up. Open Face Booths

82 6 W 7 High 6 Deep - $2, w 12 High 6 Deep - About $5,000 dollars 18 w x 7 high by 6 Deep - $5,871 dollars. Enclosed Truck/ Large Industrial Booths Cross Draft 14 Wide 10 High 24 Deep - About $12,500 dollars Cross Draft 20 Wide 16 High 34 Deep - About $29000 dollars Down Draft 14 Wide 10 High 24 Deep - About $16,000 dollars Down Draft 20 Wide 16 High 30 Deep - About $35,000 dollars Automotive Paint Booths Basic single skin paint booth without curing capabilities 14 w 27 deep 9 high - About $14000 Automotive paint booth with cure capabilities 14 ' w x 9 ' high x 27 ' deep - about $50,000 - $65000 dollars Factor # 5 - How much Duct work will your spray booth need? Ductwork pricing will come down to two things. How big is the duct you will use and how long of duct runs will you require. Plain exhaust duct (the typical duct that is used with a spray booth) will range from $15 - $60 dollars per foot for the smallest to largest duct runs. If you have long runs of duct and larger diameter duct you may need spiral duct which is higher expense ranging from about $36 dollars a foot to $125 dollars a foot for large diameter duct. If you have multiple elbows or a really long exhaust distance you sometimes will have an added expense of a exhaust fan designed for high static resistance. There can also be a small added expense for an access duct that allows for cleaning of the booths exhaust fan (which is highly recommended). Factor # 6 - Who is manufacturing your paint Booth? There can be slight variances in the cost of paint booths. Additionally you will want to make sure your paint booth meets all national codes, which you can read a good overview of national code compliance here. Each manufacturer will have varying costs but should be within 10-15% of each other typically and if they are not you will want to see if one company has added features like startup assistance, a different air make up size, different duct lengths, or different features in your spray booths control panel. A big factor in choosing a paint booth will be the expertise of your local support company which is always valuable and a well known, highly regarded manufacturer. By evaluating all these costs you can better assess the cost of a potential paint booth project. You will also be able to have a rough idea

83 of what to expect on a paint booth's price.

84 How Much Does a Paint Gun Cost, A Complete Guide Based on Different Gun Types The Short Answer How much a Paint/Spray Gun Costs depends on the Class of Spray Gun but Prices vary for A Reason It can be hard to understand why a spray gun like the Devilbiss GTI Millenium can cost twice as much as a Devilbiss FLG 4 or a spray gun like a Satajet 5000 can cost even more than the two guns mentioned. This article will talk about costs of different costs of spray guns, what to expect when you use them, and why their prices are different. In particular we will be comparing HVLP Spray Guns, the principals apply to conventional spray guns as well but pricing for Conventional Spray Guns will be less overall than HVLP. Specifically we will evaluate three classes of spray guns including Throw away or Budget Class, Economy Class Spray Guns, and Premium Class Spray Guns. Throw Away/ Budget Class Paint Guns This class of spray guns would include Harbor Freight Spray Guns which can cost anywhere from $10 - $30. They are very affordable and can be a good fit for certain needs. With a spray gun at this price you can expect a few things to occur that allow it to be so affordable. Transfer Efficiency will be less than a higher quality gun. Even though

85 the gun may be defined as HVLP you will typically waste more paint with this gun than a higher end HVLP Spray Gun. This is primarily due to the engineering design will not be to the same quality standard as an economy or premium gun. The Spray Finish Achieved will be less fine. The greater the atomization of the paint particles the better a finish. Compared to a economy or Premium quality spray gun these guns will not have the same degree of atomization. This will be most evident if your looking to achieve a Top Tier finish, like in automotive painting. The Gun will not Be Repairable. A budget / throw away class spray gun will not have parts to rebuild the spray gun if it starts having issues like uneven spray patterns, paint dripping from the spray gun tip, or an altered spray pattern The Spray Pattern will be smaller - With each higher cost class of spray gun the total spray gun pattern will improve with higher quality atomization throughout the spray pattern There will be no options for the Air Cap and Fluid Nozzle - Fluid nozzles and Air Caps allow you to adjust the amount of paint your applying to a target as well as the atomizaton of the coating. For an overview of selecting an air cap or fluid nozzle you can review this article. Best use is most likely for a one time project where finish quality is not huge concern. Economy Class Paint Guns Moving up from the budget class you get into the economy class which includes guns in the $100 - $250 dollar range. Typical models include guns like the Devilbiss FLG 4, Binks SV 100, and Sharpe Finxex This class of spray guns can be perfect for the more routine projects. Maybe doing a project one to two times a week or even routine weekend projects. Here is what to expect from this class of spray guns Gun will be better able to be repaired than the throw away class of spray guns, you will not have to ever throw the spray gun away - A economy class spray gun will typically have options for rebuild kits (which will resolve issues of paint leaking from the tip of the spray gun). You will also be able to replace fluid nozzles, air caps, and fluid needles. Having these parts as replaceable will mean you will never have to throw away your spray gun. Spray Pattern will be more uniform than throw away class with better atomization - With an economy class spray gun you can expect a finer atomized coating resulting in an improved finish. The pattern will also remain consistent for a longer time due to higher quality materials, better engineering, and machining that go into manufacturing of this class of spray gun. Transfer Efficiency will be better - A economy spray gun will use less

86 paint than a throw away budget gun and will perform like an HVLP spray gun is meant to (with about 65% transfer efficiency). Spray Pattern Will Be Wide, Atomization will not be quite as good as Premium class - With a economy class spray gun the spray pattern will be similar to a premium class gun (from inches depending on the air cap and individual gun). There are Fluid Nozzle and Air Cap Options - A economy class spray gun will have a few different air caps to choose from and a variety of fluid nozzles. This allows for a greater degree of choices which will allow for a greater diversity of rates of coating application and atomizaton. This will provide increased control over your painting work. Premium Class Paint Guns The top of the line Spray Guns like a Satajet 5000, Binks Trophy Spray Gun, or Devilbiss Millenium GTI Spray Gun cost anywhere between about $400 - $700 dollars. Clearly this is quite an investment for a spray gun and to be worthwhile will need to be justified. Here are a few reasons why these guns are high priced. Top of the Line Transfer Efficiency, least paint waste - A premium spray gun will apply the coating most effectively as it will have the highest end engineering of the three classes of spray guns. Widest Spray Patterns, Finest Atomization, Best Finish - A premium class spray gun will have the widest spray patterns available with the finest atomization. Premium class spray guns will routinely have 12 inch spray patterns with the best atomization. To Achieve the Best Atomization these spray guns will consume the most CFM typically at the air cap. Most Repairable of all the guns - Premium spray guns will allow complete rebuilds of the spray gun down to the spray gun body itself. This makes a premium class spray gun to never have to be thrown away. Greatest variety of fluid nozzles and Air Caps - A premium class spray gun will have a large variety of air caps and fluid nozzles. This will provide the greatest control over fan size, atomization, and application rate of your coating. Additionally, it will allow for spraying of the greatest variety of coatings. Premium guns can often times be used in multiple ways including conventional, HVLP, and LVMP within the same spray gun. Ultimately a top of the line spray gun is perfect if you will use it daily because your an automotive, fabrication, or manufacturing worker who paints daily. It can also be a good fit if you are a avid hobbyist, or someone wants the best finish possible. Photo courtesy of Svilen.milev (Own work), via Wikimedia Commons Further Resources

87 For a great video comparison of an economy class vs Premium Class Spray Gun check out the Gunman's review where he compares a Devilbiss GTI and a Carmix Spray Gun.

88 How Much Paint Will A Gallon of Hand Applied or Sprayed Paint Cover If you are involved with painting whether it be as a contractor, home owner, or production shop employee it will be critical to know how many square feet you can expect out of a gallon of paint. This will allow you to properly bid your material cost for your jobs. Below we will cover how many square feet a gallon of paint will cover. Coverage will depend on application method Essentially there are multiple ways coating is applied including Spray Guns, Airless Paint Sprayers, Electrostatic spray Equipment, or hand applied. Each one of these methods will yield a different rate of coverage and have different benefits and drawbacks. For a good overview of spray guns this article covers their differences and benefits as well as drawbacks. For an overview of airless application equipment vs spray guns this article provides a good overview. Finally if you want to learn about Electrostatic this article provides a good overview. The reason for differing coverage rates is due to the efficiency that coating is transferred to your product. Overview of Transfer Efficiency of Different Application Methods from highest to lowest

89 Hand Applied - 100% efficient though much slower than spray applications Electrostatic Spray Gun - Transfer Efficiency Between 85-95% efficient HVLP Spray Gun - Around 65% efficient Airless Paint Sprayer/ Conventional Spray Gun % efficient Math To Determine Coverage Will Depend on Type of Painting Being Done For Painting a building, home, or office by hand you can use this calculator below or if you have your technical data sheet this article has a calculator to determine how much paint you would use spraying vs hand applying any coating It is assumed coating is being applied by hand in the following formula. If you are spraying the coating you would take the 350 square feet * the efficiency of your equipment to have a rough estimate of coating needed Coverage for architectural coatings is typically 350 Sq Feet per Gallon. This means if you are estimating coating for a home you will take the square footage of the room by multiplying the length of all the walls by their height. Then subtract the (width x height) of the windows and doors to give you the total surface to be painted. Take the square footage and divide by 350 to give you the approximate gallons needed. Remember this is for a single coat and will need additional paint for additional coats. Lets take a quick example: You have a family room that has 4 walls and a ceiling with two windows that are 2 feet wide by 3 feet tall. The room is 20 feet long by 10 feet wide with 8 feet high walls. Here is the math for the square feet of the room. Length of walls = 60 Multiply wall length by room height = 60 * 8 = 480 Find windows square feet by taking height x width x number of windows (or individually if different sizes) = 2 x 3 x 2 = 12 Subtract windows from room square feet = = 468 Divide room square feet by coverage for a gallon of paint = 468/ 350 = 1.33 gallons If above.5 gallons get an extra gallon of paint if less each quart is equal to.25 gallons so buy appropriate number of quarts (2 quarts in this problem) Remember the 350 square feet is an approximate number and is dependent on factors including if the drywall is new (which will absorb more paint), if it is a rough textured surface which will absorb more paint, as well as how thick the paint is applied, typically its best to err on the side of caution when estimating the amount of paint.

90 For Painting with a Spray Gun or Airless Paint Sprayer using Architectural Coatings, Industrial, Wood, and Auto Body Coatings Unlike hand painting, applying a coating with a spray gun will require different math. The factors involved with industrial, wood, and auto body coatings include percent solids of the coating, the mil thickness required, and the transfer efficiency of your painting equipment. Take the theoretical coverage rate from your paint manufacturer technical data sheet and enter into B4 Take transfer efficiency percent in decimal form and enter into B5 (see above) Enter the percent of solvent in decimal form added to the coating The number provided will be the amount of coating you can expect to get out of spraying. As you can see spraying is not nearly as efficient as hand application but it is faster and can yield a better finish. Additionally it will depend heavily on the transfer efficiency you can achieve. Of the factors you can control transfer efficiency is the only variable that can be improved by using proper technique and equipment. Photo by YoctoArts (YoctoArts), via Wikimedia Commons

91 HVLP Spray Gun Problems and Their Solutions HVLP Spray Gun Problems and Solutions Spray Gun is Spitting Check to make sure your fluid nozzle is tight if not tight snug it with the appropriate wrench Check to make sure you have sufficient material in your gravity or suction cup or in the pressure pot if not fill as needed Check that you are not leaning to far in a direction with the spray gun if your using a suction or gravity fed spray gun. If material is not fed into the gun it will cause a spitting pattern. If you need to be able to paint in different positions consider a liner system like the Dekups Obstruction in fluid passage or fluid hose: Flush with an appropriate solvent Heavy Pattern on Top or Bottom of Spray Pattern Fluid passage is partially blocked - Clean appropriately Air Cap Horn plugged - Clean the Air Cap with a solvent Heavy Right or Left Sided Pattern Air Cap is plugged on left or right side - clean with appropriate solvent Fluid tip is partially plugged - clean appropriately To determine if obstruction is on air cap or fluid tip spray and turn the air cap if the pattern reverses the issues in the air cap if it doesn't reverse issue is with the fluid nozzle. Remedy is to clean air cap or fluid nozzle. If cleaning doesn't work you may need to replace the air cap. Unable to Get Round Spray Spreader screw not seating properly - clean or replace the spreader screw Air cap retaining ring is loose - tighten appropriately Will Not Spray No air pressure at the spray gun - increase air pressure, check air passage for any obstruction Fluid Adjustment Needle needs opened Fluid too heavy for gravity or suction feed - Increase fluid nozzle size and consider adding thinner

92 Paint Bubbles in Cup Fluid tip not tight - tighten the tip Fluid Leaking from Cup Tighten cup lid Lid is dirty causing it not to tighten well, clean the lid The lid could be cracked - replace if needed Sandpaper appearance of coating Inadequate coating be supplied - increase fluid pressure or use a larger nozzle Air pressure to high - reduce appropriately Painting too far from target - move closer Moving to fast - slow down Excessive Over spray You may be going past the PSI limit at the air cap - reduce air pressure Gun may be to far from target- adjust appropriately You may be arcing to much when spraying - check out a good overview of how to spray Fluid Leaking from Packing Packing nut needs tightened Packing nut is worn and needs replaced Fluid Leaking from front of the Spray Gun Fluid needle and Nozzle worn Fluid tip is clogged - clean appropriately Packing is dry - lubricate with appropriate lubricant Runs and Sags To much material - reduce nozzle size or fluid pressure Material to thin - reduce thinner use Gun tilted on an angle Orange Peel (Thick Dimpled Finish) Not enough atomization air pressure Not moving fast enough when painting To fast of fluid flow reduce fluid pressure or fluid nozzle size Surface oily and not properly cleaned Improper thinner being used

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94 HVLP Turbine Vs Compressor HVLP Spray Gun What is a Turbine HVLP Spray Gun and What is a Compressor HVLP Spray Gun? A turbine HVLP Spray Gun is an independent system that utilizes a turbine to generate the volume of air that an HVLP Spray Gun requires to spray. The turbine draws sufficient air into the unit which is then transferred through the hose which provides the air needed for atomization. A compressor fed HVLP Spray gun utilizes compressed air generated by the air compressor to feed the required volume of air to the spray gun. If you are trying to determine the proper compressor for your spray application here is an article covering air compressor sizes and types for spray guns. What are the Pros and Cons of a Turbine HVLP Spray Gun Pros Portability - A turbine HVLP Spray gun is self contained and can be used anywhere an electric outlet is available. This makes the turbine unit ideal for on site painting work. Affordable - A Complete Turbine HVLP Outfit will cost around $1000 dollars, compared to a HVLP Spray gun and Compressor which can cost approximately $ for the outfit. Cons Limited to Suction, small pressure cup (no pressure tanks available),

95 and Gravity Fed application methods: To better understand the pros and cons of gravity, suction,and pressure feed spray guns here is an overview Limited to HVLP Application method What are the Pros and Cons of a Compressor and HVLP Spray Gun? Pros Can handle multiple painters if your compressor is big enough Allows for use of conventional and other spray gun technologies Long life under frequent use Cons Initial cost of the compressor is high Not portable Which is Right For You? If you need portability for field work that would make sense to use an HVLP Spray gun over an airless or air assist airless outfit because you will be spraying smaller targets and smaller volumes of coating then a turbine unit is a great idea If you will be painting in a stationary shop, want to have diversity with the spray gun technology you will use, or want to be able to support more than a single painter then a HVLP Spray Gun and Compressor is ideal.

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97 Gravity Feed Spray Guns vs Suction Feed Spray Guns Gravity and Suction are one of three ways to feed a Air Fed Spray gun. Gravity and Suction fed spray guns allow for a lot of benefits but also have drawbacks. We will cover the advantages and disadvantages of gravity and suction fed spray guns. If you want to evaluate between gravity, suction, or the third style of air spray gun known as pressure fed you can check out this overview article. Gravity Feed Spray Guns Gravity fed spray guns allow for smaller batches of coating to be used at a time. They are also quick and easy to cleanup. They provide fine atomization and can be used effectively with all types of spray guns including HVLP, LVMP, or Conventional. The main disadvantage is that they require material to be able to flow on it s own. Practically this means that heavy body coatings will not spray well with a gravity fed spray gun. For a coating to apply well with a gravity fed spray gun it should be able to run off the end of a stir stick easily without excessive thinner. If you have to add more paint thinner than recommended by the Technical Data Sheet for the coating, it would be better to think about a pressure fed spray gun. Pros Easy cleanup Affordable (around $400 - $700 dollars less than Pressure Fed Spray Gun but similar to suction fed spray guns) Achieve a fine finish Able to have slower fluid amounts delivered which can be ideal for smaller projects and touch up work Able to change colors quickly with a disposable insert liner Better control of atomization air compared to a suction fed spray gun Cons Smaller amount of material than pressure fed (same as suction fed) Painters sometimes do not like the weight of the paint on top of the gun Limited control over fluid delivery (controlled by changing fluid nozzle sizes) Cannot spray heavy bodied coatings well Common Uses

98 Automotive painting Wood Finishing on Smaller Projects like individual cabinets or furniture pieces Used for color matching in high production facilities Metal Fabrication touch up painting Frequent color changes with inserts like Dekups Suction Feed Spray Guns Suction fed spray guns use the air that passes over the coating to draw material through the pickup tube of the suction cup and through the nozzle. One of their greatest advantages is ease of use. Due to the way the gun uses air to pick up coating it will typically automatically have the correct atomization air pressure set by having the pressure high enough to supply coating. This can also be a disadvantage because you cannot control the atomization air pressure like you can with a gravity fed spray gun. The suction fed spray gun will cost about the same as a gravity fed spray gun. People also often say they prefer the comfort of a suction fed spray gun over a gravity fed spray gun because the material is below the gun and not above it. Another disadvantage of a suction fed spray gun is that it will not allow for quick color changes as easily. Pros Easiest to learn how to use Affordable Greater comfort than gravity fed spray guns Can achieve unique finish effects and works well with specialty coatings like adhesives Cons Less control over atomization of air compared to gravity fed spray gun Difficulty with heavy bodied coatings Not as fine as a finish due to needing larger fluid nozzles Not as easy to perform color changes Uses Although it has been used for all kinds of coatings we recommend it in the following situations Adhesives application for low viscosity coating Longer paint times with small batches that the comfort is critical and finish quality is not huge concern

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100 Electrostatic Paint Sprayer and Spray Guns Their Pro's and Cons What Electrostatic Painting Is Electrostatic painting is applying a negative charge to a coatin. Your intended target is grounded creating a neutral charge. The negatively charged coating seeks ground and therefore is attracted to the target. This results in a "wrapping" effect where excess coating rather than bouncing off the target adheres to the target resulting in significant over spray reduction. Electrostatic painting utilizes basic application methods including HVLP, Airless, and Air Assist Airless methods but adds the electric charge to improve transfer efficiency, it is also used with powder coating to cause the powder to adhere to the product With automatic electrostatic spray equipment there are also rotary discs and bells which utilize rotational speed to atomize a coating (unlike the other technologies that use air or fluid pressure). Benefits By far the greatest benefit to electrostatic application equipment is the reduction of coating waste. In ideal settings electrostatic equipment can have upwards of 90% transfer efficiency. This can result in thousands of dollars of cost savings. For a general idea if your coating costs 100 dollars a gallon and you were to use an Electrostatic outfit when you previously were using an HVLP or Air Assist Airless spray gun you would save about $25 - $30 dollars a gallon of paint waste. Or if you were using traditional airless equipment and changed to an electrostatic airless outfit you could save anywhere from $60- $70 dollars a gallon of paint waste. The second great benefit is reduced over spray. If you need over spray to be kept to a minimum electrostatic equipment will reduce overspray anywhere from %25 - %60 percent (the lower percent is if you are currently using HVLP or Air Assist Airless vs the higher percent is for Airless Equipment). Challenges Safety Due to the presence of electricity in your painting process safety is of great concern. The primary safety issue is that the operator and target must remain well grounded. A grounded operator causes all electricity that is created by the spray gun to flow to the coating and not to be stored in the operator. Failure to have the operator properly grounded due to standing on a non conductive surface like wood

101 pallets or on a vehicle with rubber tires can result in a charge building in the operator if the ground outlet on your equipment is to fail or the ground on the air hose were to fail, The operator must also hold the spray gun with a bare hand to prevent an electric charge from building in the operator. If the operator is not well grounded or doesn't hold the gun with a bare hand, when the operator approaches a grounded target the electric charge will seek the grounded object which can result in an electric spark, which in an area where solvent is present like a paint booth could result in a fire. If the target and everything within 10 to 15 feet of the booth are not grounded an electric charge may build in the target. This built charge can result in a spark which can create a fire. Additionally, all cleaning should be performed with the electricity, air, and fluid turned off to the spray gun. Coating Challenges Coatings have different degrees of resistance and conductivity. Resistance is the tendency to resist being charged and conductivity is the tendency to carry a charge. For electrostatic applications a coating needs to be not to resistant to charge and not excessively conductive. If a coating is excessively conductive (like waterborne coatings) special equipment (like an isolation stand) is required to allow the coating to be charged and prevent it from shorting out but isolation stands should only be used with non flammable coatings. Shorting out refers to an issue where the coating draws excessive current and lowers the voltage below an effective level. Opposed to excessive conductivity causing issues with shorting out if a coating is to resistant to a charge it will not be able to carry a charge and benefit from increased transfer efficiency. Fortunately excessively resistant coatings can be made more conductive by adding proper thinners. l. Due to these potential problems with electrostatic equipment it is recommended to have the equipment trialed or demoed with your intended coating. By giving the coating a real world trial you can be sure it will spray well electrostatically. Product Substrate Challenges Electrostatic application requires the target to be painted to be

102 electrically conductive. This means that substrates like wood, fiberglass, or plastic will not naturally work well with electrostatic application. To spray wood, plastic, or fiberglass electrostatically requires a precoat with a conductive coating that will allow the product to be grounded. In addition to the product substrate challenges you also have an effect called the Far A Day Cage Effect. The Far A Day Cage Effect is due to the fact that a negative charge will seek the nearest ground. When you are painting a corner of a product the coating will adhere to the outer edges but not penetrate into the corner resulting in uneven and even no coverage in a corner of a product. To stop the Far A Day Cage Effect you have to turn the electric off to the spray gun when your painting inside corners. Summary - When Electrostatic painting is good for your painting Needs Electrostatic can save a lot of money on coating costs. However you will want to ensure you will have operators who are attentive to safety considerations. You will also want to evaluate if you will use a coating type that is electrostatic friendly and stick primarily to a waterborne or solvent borne coating so that you do not have excessive equipment costs buying two electrostatic outfits. Finally you will want to ensure your substrate will be able to be grounded well so that coating costs will truly be reduced.

103 Complete Guide to Buying Used Spray Guns on Ebay or Craigslist Sometimes a budget can be tight and you need an affordable spray gun and often times it can be the right option for your needs. However there are a few important things to think about before buying a used spray gun on craigslist or ebay so you ensure you receive a good value and do not end up buying a spray gun that will not work well. Consider the following important factors to ensure you get a quality spray gun for your money that will meet your needs. What kind of painting will you be doing and What kind of Coating will you be spraying? - Spray Guns vary for what they are ideally suited for. Binks makes spray guns that tend to focus on Industrial Manufacturers and Wood Finishing. Kremlin focuses primarily on wood finishing equipment. Devilbiss, Sata, and Iwata all focus on the automotive industry. While they may be best suited for their defined industry it doesn't mean you cannot utilize them for different purposes. Ultimately the setup and style of the spray gun will be the critical factor in determining if it will meet your painting needs well. For a better idea of choosing the right set up of spray guns check out this article on how to choose a spray gun which will cover a lot about what the set up of your spray gun should be. Additionally you should consider whether you would prefer a suction, gravity, or pressure fed spray gun. Each style of gun will have benefits and drawbacks and will require different additional equipment. Gravity fed spray guns are most commonly used for automotive painting - they are limited if you will have to turn the gun upside down for painting (unless you use a Dekups or similar system with the correct setup). They also have to be able to have the material flow on their own. Additionally if your buying a gravity fed spray gun you will want to make sure it includes the gravity fed spray gun cup Pressure Fed Spray Guns - These guns will require a pressurized system to feed them such as a pressure pot or a remote pressure cup which if you are buying one you should make sure you have the pressure pot or a remote pressure cup (they are at

104 least a couple hundred dollars new). You should also evaluate whether the used equipment is truly a value as Binks packages 2.8 Gallon pressure Pots with a Spray Gun for about 918 dollars and comes with all fluid hose, the pressure pot, and a spray gun which can be a few hundred dollars depending on the model of gun chosen. Suction fed spray gun - A suction fed spray gun can be used well with lighter coatings. It can be used at odd angles as well. If your buying a suction fed Spray Gun. Make sure the Spray Gun has a Suction Fed Spray Gun Air Cap (NOT A PRESSURE FED SPRAY GUN AIR CAP) if it doesn't have a suction fed spray gun cap the gun will not function properly. Questions to ask the Buyer and Things to Look For - How old are the fluid nozzle, fluid needle, and air cap. These are parts that will wear routinely with use. You can quickly determine if the gun needs a new fluid nozzle or needle by asking if the spray gun leaks at all from the tip of the gun when the trigger is released. You can also ask if the spray pattern is equal on both sides of the pattern. If it is not you probably need a new air cap. Is there issues adjusting the spray pattern? If there is most likely a side port control assembly is defective. Finally inspect the gun to ensure there are no significant visual defects and if possible ask to see the gun spray! Used vs New Price - With a Used Spray gun you have to add the cost of potential replacement parts into the equation to see if it is truly a value. Also you want to try to make sure that it is a gun that is still being manufactured so that support for repair parts is not difficult. After-all many new spray guns can be purchased from anywhere from dollars and often include numerous spray gun fluid nozzles as a package for the price of a single fluid nozzle. If you have bought new vs used spray equipment is their anything I am missing or if you need help with replacement parts on your used equipment we can often help contact us today.

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106 Cross draft vs Downdraft vs Side Downdraft Paint Booths I often get asked whether or not a customer should use a cross draft or downdraft spray booth. I also often get asked what size booth they should use. The goal of this article is to cover the main styles of spray booths, the benefits and drawbacks of each style booth, and how much space you may want in a spray booth based on your product size Cross draft Spray Booths Cross draft spray Booths bring air through the front of the spray booth and exhaust it out at the rear of the spray booth. The major benefits to this type of booth is that they are more affordable then downdraft booths and typically easier to install because you do not have any concrete work to be performed. When accompanied with an air make up unit they are often as effective as a downdraft spray booth in providing a clean finish. The downside is that if your top priority is finish quality a downdraft will always be a cleaner paint finish because all overspray is pulled down away from the product while in a cross draft spray booth overspray at the front of the spray booth can potentially land on your product at the back of the booth. Downdraft Spray Booths Downdraft spray booths bring air in through the ceiling and down through the floor into an exhaust chamber which is exhausted at the rear of the paint booth. Downdraft spray booths will provide the cleanest possible finish. It is what is used in high end auto body

107 facilities due to the clean finish provided. The downside to downdraft booths is that they typically require a raised floor or concrete pit which can be an additional expense. If you plan the concrete floor prior to purchasing your paint booth you can install a downdraft booth at the same cost as a cross draft paint booth. Additionally with very large objects downdraft booths do not make sense because air removed is based on the length and width of the paint booth making it harder to reorient your product to reduce air removed from the building. Side Downdraft Paint Booths Side Downdraft paint booths bring air in through the roof and exhaust it out the sidewalls of the paint booth. This allows for a downdraft finish quality but doesn't require a concrete pit. It might seem like a Side Downdraft paint booth is all the benefits of the downdraft without any drawbacks (concrete work ect), but there are some negatives to a Side Downdraft paint booth. First is that it will require a lot of ductwork which can often lead to a cost similar or even more expensive than a downdraft paint booth. For example a Side Downdraft paint booth will require at least twice the number of duct runs that a comparable cross or down draft paint booth will need with longer booths even more duct runs may be needed. Each duct runs also adds an additional hole in your roof which can be a source for water leakage over the long term. An additional downside to Side Downdraft spray booths is that over spray from painting is carried back against the painter which can be annoying for some painters. A final consideration is that a Side Downdraft will exhaust a similar volume of air as a downdraft paint booth. Ultimately, f you absolutely need a downdraft finish and are limited on altering the floor of a building a Side Downdraft can be a good solution. It can also be a great solution for a smaller booth where only two duct runs would be needed and no floor alterations can be made (such as a small auto body shop). Ultimately if your choosing between a cross draft and downdraft paint booth consider the following. If you need the finest finish possible consider the downdraft. If your on a budget or do not want to alter your floor consider the cross draft paint booth. What size Paint Booth Do I need? The size of paint booth you will need depends primarily on the size of your product. If you are buying a cross draft paint booth try to keep the width and height of the booth to the minimum you need by orienting your parts so they face deep but not wide in relation to the booth opening. The reason to keep the face opening small is that the amount of air you remove or if using a pressurized spray booth the amount you have to replace with a cross draft spray booth is determined by the size of the width and height of the face opening. A larger opening will create extra negative pressure and even remove all the heat from your building vary fast depending on your buildings size. So if your product is 45 feet x 3 feet by 8 feet you would want to consider a booth that is only about 12 feet wide but very long. As a general rule of thumb you want to keep

108 about 3-5 feet of space on all sides of your product for maneuverability so in the product mentioned above you would want about a 52 foot deep booth. Additionally always try to ask for factory standard sizes so that you select a paint booth that is not custom designed, typically booths will come in varieties of 3 foot lengths but always make sure to ask for a standard size unless it will not work for your specific situation. Air Make Ups and Cure Capabilities As we have discussed paint booths will remove a lot of air from your building and depending on the size of the booth and your building you may completely empty your building of all temperate air in minutes. If this is your scenario it can be important to replace the air your spray booth is removing. You also have to consider whether you want to add a cure capability to your spray booth. For reference sake air make up units are a large expense but cure capabilities are not that much extra cost wise. The cure capability will allow you to raise a booth to about a 160 degrees and bake the coating reducing product dry time by up to 50%. If you have a small shop or large paint booth or need the ability to turn product completely, or are worried about paint odor from a drying product impacting your facility, then an air make up unit can be a great idea. Consider an air make up for your paint booth if you have a large paint booth, a small shop, or if you want to be able to accelerate product dry time significantly. Photo credit: By Sebog6 (Own work), via Wikimedia Commons

109 Choosing an Air Compressor for Airless Paint Sprayers and Spray Guns Air is the key factor in using airless paint sprayers and spray guns and the largest cost is often the air compressor that is required to provide the compressed air for your spray gun or airless paint sprayer. When evaluating a compressor the key is to know your equipment's air requirements and your application needs. First will cover the air requirements of airless and spray equipment and then we will cover things to consider about the air compressor itself. Between spray guns and airless paint sprayers, spray guns use a significantly lower volume of air. When it comes to a compressor, the volume of air is what is most important, as almost any compressor will provide the pressure painting equipment needs. Typically the volume of air the compressor provides is what increases the cost of the air compressor and is important to think about which equipment (airless or a regular spray gun) is better for your application. To better understand which is right for you check out our article on when to use conventional vs airless spray equipment. After deciding on your proper spray equipment you can then be sure of the right size compressor. As a general rule of thumb for a single Spray Gun you should have around 30 CFM. However you can get away with less with the proper spray gun (around 6 CFM). The limitation will be that you will not be able to atomize heavier coatings as well due to the low CFM air cap that will have to be used to conserve CFM. With air driven Airless Paint Sprayers air requirements will depend on the fluid output and pressure of the pump. To be safe usually around 100 CFM to 130 CFM is good to have

110 available for an Air driven Airless Paint sprayer (electric and gas airless sprayers do not need a compressor). If you use a compressor that is small you have to make sure you properly match your spray equipment so that it doesn't require a lot of air. If you have a spray gun that uses more air than your compressor can supply, you will notice problems where your spray pattern will not be consistent after spraying for a while. The fix for this issue is to increase your compressor size or use a large storage tank and occasionally stop spraying so that the storage tank has the chance to rebuild pressure and volume. In addition to having enough volume of air you have to consider the type of compressor to use. For spray equipment, there will primarily be two kinds of compressor you will use, first is a reciprocating compressor and second is a screw type compressor. Their pros and cons can be read about here. Compressors come in single and two stage formats, the difference is in the volume of air per Horse power they will deliver. A two stage compressor will provide about 4 CFM per horsepower while a single stage compressor will only provide about 1 CFM per horsepower both will provide about 100 PSI of pressure, but we need volume of air more than pressure. For this reason, when considering a compressor for spray equipment it typically requires a two stage compressor to provide enough CFM. In addition to the style of compressor, you also have to evaluate where you will be working. If your working in a manufacturing plant, then a electric indoor compressor will most likely be appropriate. However if you will be working in the field, you will typically need a two stage gas driven air compressor also called a tow behind compressor. Overall, by being aware of your compressed air needs and cost, you can best prepare for your current spray equipment needs and plan for future potential growth as well. Photo courtesy of Chris Bartle

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112 Airless Paint Sprayer Troubleshooting Airless Paint Sprayers can be tremendously helpful when it comes to high production needs. However, they also can be a headache when problems occur. In this article we will cover the most common airless sprayer problems and how to fix them. Problem 1 - I get inconsistent spray patterns This is often called a wink among painters where the pattern moves from consistent and even to fluctuating between narrow and wide. When this occurs it is most often caused by a inconsistent traveling of your fluid section's piston. The fix for this issue is most often to replace your fluid section packing's. In addition it can be due to a ball check not properly seating which in this case will require changing out the ball check and seat. To determine if the ball check and seat are worn a visual inspection can often show you by looking for a gap between the seat and ball when they are placed together. You should also check the fluid pick up tube and internal filters for any clogs, if the filter at the end of your pickup tube or internal to your unit are clogged they will cause inconsistent spray patterns. The final but least common contributor to airless pattern inconsistencies is a worn rod that the packing's travel along. In most cases, the first step is to replace the packing's, second you replace the ball seats or checks, and finally the rod. If you want to be extra sure your pump will have no issues you can replace all three components.

113 Problem 2- I am having trouble with my pump pressure (its building up to high or I can't get it to build high enough). If you airless pump's pressure is building up to high and your using an electric airless it most likely an issue with a transducer. The transducer is a sensor that acts to control the pressure in your airless sprayer, if your pressure is to high you most likely need to replace the transducer in an electrical unit. If you are having trouble building and maintaining pressure the most common causes are due to pressure failing to be retained and built, this is most often caused by issues with your ball check and seat. It can also be caused by a blocked filter on the end of your pickup tube. Problem 3 - My spray pattern has an uneven appearance all the time (its thin or not existent in the middle and heavy at the top and bottom of the pattern) This is most often due to not having enough pressure applied to your coating. First try to increase the pump pressure and if that is not the solution sometimes you need to try different tip sizes (if you find the coating is not flowing increase the tip size or if the pattern is too heavy reduce the tip size). The other issue that can cause this is that your tip on your airless spray gun has worn to excessively causing changes in its opening size resulting in a change to your pattern. By knowing these three common problems that cause airless paint sprayers to not work correctly you can get your airless back to great working shape, if you prefer not to we also can help with repairs or part guidance. Image Courtesy of Teresa

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115 Choosing an Airless Paint Sprayer Airless paint Sprayers are the backbone of paint contractors and industrial painters work, they allow you to paint a high volume of product in a short time. They also often represent one of the larger expenses a contractor may make. With their critical role in your painting it is important to select an airless paint sprayer that will meet your needs at a proper price. What we will cover are the most important things to consider when choosing an airless paint sprayer. Current as well as future production needs Ideally your painting capacity need will increase as your business grows over time. This is why it is important to consider both your current production needs as well as the future needs. In particular how many Gallons of paint per minute do you want to be able to handle? If your primarily painting drywall in homes an electric airless most likely suits your needs, however if long term you move into large high rises you may need the option of increased production (a larger Gallon per minute ability). By thinking through your production needs in the present and future you can better prepare to ensure you have sufficient pump capacity to handle your painting needs. Typically we recommend oversizing your paint sprayer pump a minimum of 30% higher than your highest production would require. In fact you can review an article I wrote previously on choosing a pump for an airless paint sprayer here to better understand the importance of a proper pump size for an airless sprayer. Airless paint sprayer power source Airless paint sprayers come with Gas, Air, or Electric Drives. Each is suitable for different purposes. Air driven airless sprayers offer the largest GPM capabilities typically but require compressed air to operate. Electric Airless provide the smallest Gallons per minute but are ideal where you are in an area that a gas engine would be inappropriate (like the interior of new construction). Gas driven airless units are portable and have a relatively high Gallon per minutes output, they are typically ideal where you need production and portability. Airless Sprayer Pressure Requirements Pressure in an airless paint sprayer provides two benefits. The first is the ability to atomize heavy bodied material. Airless paint sprayers utilize fluid pressure to atomize coating and therefore require a lot of pressure to atomize heavy materials like zine. The second reason pressure can be important is if material must be pumped over a long

116 distance. If your material will be pumped a long distance before being sprayed you will need the higher pressure pump to be able to sustain a proper pressure over long lengths or heights of fluid line. Local Support and Parts Availability No matter who builds your airless paint sprayer there will be breakdown with use. Packings, ball checks, or other parts will wear over time and need replaced. The strength or weakness of local support can be important in evaluating airless paint sprayers. If a local company has the parts for repair on hand as well as the talent to rebuild your pump, you don t have to wait to return to production as long then if you have to order parts online and then try to properly service the unit. Company Choice Airless Paint Sprayers are provided by a lot of companies but the most common include Graco, Wagner, and Titan. Each has a different focus with Graco and Titan focusing primarily on commerical and industrial accounts while Wagner tends to be focused more toward the consumer market (though this is a generalization and each company cross over into different markets). By considering the factors mentioned above you can ensure you receive the best solution to help you with your airless paint spraying needs.

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118 HVLP Spray Gun Vs Conventional Spray Gun VS LVMP Different spray guns have different benefits that stem from their air caps. Air caps are critical to atomizing your coating well and each type of air cap atomizes in a different way. Each cap also results in more or less transfer efficiency. As I have mentioned improving transfer efficiency is one of two keys to reducing finishing costs. In this article we will cover the differences between each of these air caps, there benefits, and there drawbacks. HVLP Spray Guns HVLP stands for High Volume Low Pressures. They use a lot of volume of air and convert it to a low pressure. The benefit is a soft spray that reduces overspray, which reduces coating waste and saves on paint costs. The drawback is that thick coatings are often not able to be atomized well. Heavy body coatings that will not atomize with HVLP well include Epoxy and Zinc Coatings. They are about twice as efficient as Conventional Spray Guns applying about 65% of your material to the target. However a high quality HVLP Spray gun will usually cost more than a conventional gun (anywhere from dollars more). Conventional Spray Guns Conventional Spray guns utilize air at a higher pressure than HVLP spray guns. The benefit is that regardless of how thick the coating is it can be atomized by increasing the pressure and atomization can be higher than HVLP. The drawback is that transfer efficiency is significantly reduced to around 35 percent which results in extra coating waste and

119 increased coating costs. If you have heavy bodied coatings like glues, epoxies, and zincs conventional air caps often make the most sense. It is also the perfect option for a tight budget as they are cheaper than HVLP and LVMP guns. LVMP Air Caps LVMP stands for Low Volume Medium Pressure. LVMP spray guns takes a smaller volume of air and produces a medium pressure. In essence it uses less air than an HVLP air cap but with a slight bit more pressure than HVLP. The end result is that transfer efficiency is similar to HVLP air guns (around 60%). An LVMP gun will not atomize quite to the extent of a conventional gun (which atomizes more than any other air gun) but will provide a finer finish than HVLP as it uses more pressure to help break the coating apart well.. This can be a great set up for wood stains and similar thin finishes that need the finest atomization. The drawback to a LVMP gun is that it is often not listed as meeting codes for emissions reduction. If you are under watch for emissions make sure to speak with your states environmental agency or do not use a LVMP air cap. They are also more expensive than Conventional Spray Guns. I

120 HVLP, LVMP, and Conventional Air Caps the Advantages and Disadvantages of Each Conventional Air Caps Conventional air caps allow for the best atomization heavy body materials are easily broken up with conventional air caps. However, conventional spray guns only have about a 30 percent transfer efficiency meaning you have significant paint waste. Additionally if you are under watch for excessive emissions conventional guns will cause higher emission of VOC s due to the lower transfer Efficiency. They are the most affordable of spray guns costing about 1/2 the cost of higher quality HVLP Spray Guns. They use a lot higher pressure which allows them to atomize a wider variety of coatings. HVLP Air Caps HVLP air caps are highly efficient with up to 65% of your paint hitting its intended target. They use a high volume of air at a low pressure to break apart coatings. They allow for great savings on your coating use and help with emissions reduction. However they are not able to atomize heavy body coatings such as epoxies, heavy glues, or zincs as well as conventional caps. LVMP Air Caps A LVMP spray gun allows for spray finish quality similar to conventional guns, it atomizes your coating more thoroughly but will not atomize heavy bodied coatings as well as a conventional gun. LVMP air caps have a mid pressure which allows them to atomize a bit finer than an HVLP cap, this makes them a great choice for wood finishes where a finer atomization is desired. It is also more efficient than a conventional spray gun at about 60% efficient.. With so many positives why is it not the only spray gun air cap used? Mainly because if emissions need controlled the LVMP air cap will not meet regulations for emissions restriction requirements in painting in many states. However

121 if you are not under emission restriction, need a fine finish, and can sacrifice slightly on transfer efficiency an LVMP air cap is a great option. General Summary - Conventional excels at breaking apart heavy materials but is not as efficient as LVMP and HVLP. HVLP is the most efficient of spray guns and will waste the least paint. A LVMP spray gun allows for high transfer efficiency with a bit of a finer breakup than HVLP. Ultimately which of these caps is the right for your application will come down to what you are spraying, your goal for the finish, and if there are any regulatory concerns about your emissions. By knowing this information you can best match your air cap for your spraying needs and achieve the best finish you desire while not wasting excessive paint.

122 Important Considerations for Spraying Waterborne Coatings Waterborne coatings have a lot of benefits with the greatest potential benefit being that they are better for the environment and are looked upon with greater preference by government agencies responsible for Environmental Regulation. With these advantages there are a few challenges that they come with that are important to consider if you will be spraying waterborne coatings. 1. They require unique application equipment. If your coating is water based they will rust your typical coating handling equipment. This is because galvanized metal, which most pressure tanks are made of, does not hold up well with waterborne coatings. The solution is you have to use a protective covering like a pressure tank liner or purchase stainless steel outfitted equipment. Due to the likelihood of the equipment coming in contact with the coating routinely even if you use a liner, it is usually better to buy stainless steel outfitted application equipment. 2. They have unique properties that result in unique application requirements In particular water based coatings require significant and meticulous prep work to their target surface before application. Water based coatings are a bit more sensitive to any surface contaminant that is not thoroughly removed prior to painting. This is why solvent based coatings are often still used in industrial context, it can be difficult to properly maintain a clean enough paint environment for water based coatings in industrial painting settings. 3. They may not provide the durability that solvent based coatings do Sometimes water based coatings will not withstand heavy abuse that can be encountered in tough industrial and construction environments. This is due to the process of how solvents form adherence to the surface that differs from the process that water based coatings use to form a bond to their surface. How about you have you sprayed any waterborne coatings? What tips, troubles, and learning did you have to do to properly apply them?

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124 How to Avoid Spray Equipment Breakdown Isn t it the worst when you go to pick up your spray gun or system and instead of a nice fan with well atomized paint you get something different. Maybe the pattern is not even, or the material will not atomize correctly, or worse the entire system is not allowing any paint to flow. When these kind of issues happen it s important to evaluate why. We will go over the most common spray equipment problems, there cause, prevention if possible, and solution. Spray pattern is uneven most commonly this is due to a faulty air cap. To check if the air cap needs replaced spray and switch the cap 180 degrees. If the pattern is again uneven but on the opposite side your air cap is most likely in need of replacement. You can always try cleaning the cap to ensure it isn t just a clog in an air passage. Fluid leaks from the gun tip This is most commonly due to a poor seal between the fluid needle and nozzle. You typically will need to replace both the nozzle and needle as overtime the components wear and allow paint to drip from the front of the gun. Prevention of this issue is keeping fluid pressure in pressure fed systems to the minimal adequate amount. Excess fluid pressure causes faster wear of the fluid nozzle and needle. Additionally with viscous materials it is often a good idea to use harder metal components like tungsten carbide nozzles and needles. Air is constantly leaking from the gun This is typically due to packings that are behind the trigger being faulty. When these packings go bad air is able to escape around them. There is not much you can do to prevent this issue. However, replacing them is simple enough. The entire system will not supply any paint This is usually do to hardened paint in your gun or pressure tank. The most common culprit of this is leaving paint in longer than the recommended pot life or poor cleaning of your equipment. If this happens you typically at least have to soak your components in solvent or sometimes have to replace components that are packed with hardened paint. Avoidance comes from allowing adequate time to clean equipment prior to pot life expiring. Additionally it is usually a good idea to leave the fluid lines wet with thinner which will prevent any residual paint from forming partial blocks. To better understand the concept of cleaning your equipment please reference this article.

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126 How to Maintain Your Spray Equipment Caring for your spray equipment is critical. By caring for your equipment properly you can use it for months and even years on end before having to completely buy a replacement for your equipment. We will discuss the important steps in properly cleaning spray equipment. First, use the proper cleaner. Your coating supplier will provide a recommended cleaner for your spray equipment if you stray from this recommendation, you may not be able to clean at all or you may not get the equipment as clean as you would hope. Second follow a proper cleaning method. To properly clean spray equipment will depend on the type of equipment, so this post will cover air spray equipment and then will cover airless equipment in a future post. With air spray equipment it will depend on if your equipment is part of a pressure fed system, suction fed equipment, or gravity fed equipment. With a gravity fed spray gun you will want to empty any residual paint from the gravity cup into a waste container. You will also want to clean the gravity cup out. Next you should run the appropriate cleaner through the fluid chamber until the fluid chamber is clear of any material, the fluid coming out will be the same as the clear color of your cleaner. Your final step should be to remove the air cap and wash it in solvent. With a suction system the process will be similar. Empty your paint into a waste cup, clean the suction cup, place solvent in the cup, and connect the gun to air. You then spray the gun into the booth filters until the material coming from the gun is clear. Finally you clean the air cap. This will ensure the gun has been properly cleaned. Pressure systems are slightly different to clean than gravity and suction systems. If you have a 2 quart cup you empty the cup of all remaining material. Disconnect your cup from the air source and place solvent in the cup. You can then connect the air supply again but turn off the atomization air and leave only fluid pressure to the cup on. You should then continue running cleaner through the fluid hose until the material leaving the spray gun tip is clear (this may take a few batches of solvent). After clearing the fluid line you can place the air cap into solvent for cleaning. You should leave the fluid in the line to prevent any residual coating from hardening. With a pressure pot of larger size you can perform a back pressure technique to remove coating from the line which will help reduce solvent use. To do this you remove all fluid pressure to the pot and remove the lid from the pot but leave the fluid tube of the lid still inside

127 the pot. You leave the atomization air on but place your hand with some pressure over the air horns then pull the trigger to allow air to flow. Spraying Coatings vs Hand Applying Coatings Having only atomization air on and your hand over the air horns will force fluid back to the pressure pot and help save coating waste. After you have removed the most fluid possible from the fluid line you then would empty all the paint in the pressure pot. Then place clean solvent in the pressure pot and run it through your line without any atomization air but just fluid pressure until fluid coming from the fluid nozzle is clear. Your last step is again to clean the air cap in solvent, ensuring you leave the fluid in the fluid hoses. Before we can compare the two types of coating application we first If have you to are define using them. epoxies Spraying or other is material a term that that refers is prone to utilizing to hardening there equipment are a to few take additional a coating things and to apply remember. it. The coating You have is supplied to leave to a enough gun that time introduces to clean air your or uses equipment. pressure Do to not break try to up spray the paint right to up form to a the fine amount finish. Hand of time applying your material's constitutes pot using life is. a Pot roller, life brushes, is how long or your the material physical will hands last to once apply mixed a coating before to it a starts surface. hardening. Below we You will may list the also want primary to do benefits one additional of each and step the in drawbacks your cleaning, of each clean type the of fluid coating line and fluid application nozzle method. as mentioned above and then disassemble the spray gun's fluid nozzle and fluid needle. This will allow you to ensure the complete fluid chamber, fluid nozzle, and fluid needle have all been properly Spraying cleaned from all material. By Pros properly caring for your equipment you will allow for smoother operation, better painting, and consistent finishes. A final step to complete Speed Spraying is to routinely is extraordinarily review your fast equipment compared for to any hand potential application need of for coatings components to be replaced. In our upcoming posts we will discuss in detail parts that are most likely to wear and some signs that they are worn. Finish Quality Brushed or rolled finishes cannot approach the appearance that a sprayed coating achieves. This is one reason why a car finish is sprayed rather than rolled. Reduce labor cost Spraying saves a lot of work time and if employee pay is a high expense spraying will allow them to produce more while painting less. Cons More paint waste Spraying will have what is called overspray which is paint that does not adhere to the targeted product. Overspray has to be controlled and properly removed from an environment to ensure safe painting. Difficult with certain coating types A few rare coatings can be challenging to properly apply using a spray outfit. Particularly if your material has a very short pot life as a single component material or is extraordinarily thick spraying can be challenging to properly have the material applied Hand Rolling Pros No paint waste Hand rolling will eliminate virtually all paint waste

128 Increased coating application control By hand applying coatings you can have greater control over the thickness of coating you apply, typically referred to as millage. Cons Decreased production Increased Labor Cost Hand Application takes significantly longer than a spray setup Reduced finish quality Brushes, hands, and rollers all leave marks on your finished part resulting in a rougher appearing finish than if a coating is spray applied

129 When to use Conventional Spray Guns vs Airless Paint Sprayers Conventional and airless are pretty equal when it comes to transfer efficiency. If they are equally efficient you may wonder why you would pick one over the other, that is what I intend to answer in this article. The primary question you have to ask when choosing between a conventional and airless application is what is most important for you, production or control and finish quality. The reason is that between the two equipment types conventional air spray allows you to control the painting process more than airless spray. WIth a conventional spray gun, particularly using a pressure pot, you have control over both your fluid pressure and atomization pressure. This allows for you to determine the amount of paint you want to supply as well as the degree of breakup or atomization you want to achieve. The downside to conventional spray is that you will not be able to achieve the volume of paint being sprayed that you can with an airless sprayer. For example an airless sprayer ranges from 0.3 gallons a minute up to 2 gallons a minute. However the ability to control that rate is dependent on the fluid tip applied leaving little room for adjustment of the amount of fluid supplied. A conventional gun on the other hand usually has a high side output of about 0.35 gallons a minute. Within the conventional gun you can control fluid output by changing tip sizes as well as adjusting fluid pressure on your pressure pot. The airless is limited to fluid tips and operator technique to control application speed. To summarize, by being able to control fluid output and air atomization you can achieve finer finishes and have better control of the paint you apply because of control of fluid rates. With an airless you will have greater production but unable to control the process as well which can lead to paint quality issues especially with inexperienced painters.

130 Documentation Saves Time and Money in Spraying Applications If you are in a production setting for spraying you need to have a record of important variables that effect the way you spray. The reasons for keeping a written record are a multitude but include helping to reduce finish quality differences, solve issues related to equipment malfunctioning, and ensure repeat-ability of your finish. Below we cover why a written record can make a great difference in each of the areas mentioned above. 1. Reduce finish quality issues If you do not have a record of important information including paint information (viscosity of the paint, amount of paint mixed), the environmental conditions when you sprayed (air temperature, humidity), and the spray gun set up when you sprayed (nozzle size, air cap utilized, gun type used, fluid pressure, atomizing pressure) it will be a long process to resolve an issue with finish quality. Sometimes finish quality issues are related to an external factor such as contaminant entering your finish either through your air supply or the external environment. However if the variables that I mentioned to write down are not controlled for then those issues must first be explored before moving to the external factors or air supply issue. In the end this costs operator time when troubleshooting must happen and this costs both money and production. 2. Equipment malfunctioning if a spray gun seems to be doing something different than it did before it could be due to the guns set up or the coating performing differently when sprayed. To be able to isolate the most likely cause of this it is easier when we can be sure that other variables have been controlled for such as the environment and the setup of the equipment. If we do not control equipment and the spray environment we have to then try to look back to discover the gun setup used as well as ensure the spray environment is the same in the current configuration. Again this costs both in production and money. 3. Repeat-ability of finish This is by far the biggest benefit to having a written record of the coating your using, the temperature of the environment, humidity in the atmosphere, amount of paint used, solvent mixed in the paint as well as the equipment setup. By having all of this written you can ensure the same finish regardless of who the operator is, assuming they have proper spray gun technique. It allows an operator from guessing on settings and procedure for spraying which ensures a process that yields the same result. If your hoping to reduce costs, improve production, and ensure repeatability of a finish write down the pertinent details so that you can be better assisted if equipment issues occur as well as receive a repeatable finish.

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132 How to Know if You Need an Air Make Up Unit for Your Paint Booth What Air Make Up Units Are Air make up Units are air replacement systems for spray booths. They provide heated air to the booth that is equal to the air that is removed due to your exhaust fan running. Air make ups can also be equipped with advanced controls to allow for the booth to add a bake cycle to your painting process. Having air to replace the air removed and the potential to have a low temperature bake cycle is nice but it is also quite expensive, often it can cost as much and even more than the whole spray booth itself. With cost in mind when do we know if it is necessary or worth adding heated make up air to your paint booth, that s what we'll cover in this post. Variable 1 Is there a need for increased production in your manufacturing process Often your painting operation can be the bottleneck for your facilities production. The key variable is what is the dry time for your product and how much space do you have for your product to dry. If you do not have space for an item to dry in open shop air due to needing floor space or if you want more product done in shorter time heated air with a bake cycle can be just what is needed. To know the potential production increase you can read your technical data sheet for your coatings. WIthin this sheet will be a section that states the difference in dry time when using room or ambient temperature vs a bake temperature (this temperature is typically in the mid to low 100 degree range). The difference in these times is the difference in dry time and hence indicates the change in production. If your original dry time is 4 hours unheated and 2 hours heated you can essentially double your production. Variable 2 - Air available in your shop We recommend having enough shop air to run a booth at least 20 minutes before you deplete the air from your building. This is so that you can have your shop doors closed and operate the booth without worry about busting a window from too much negative pressure. Additionally the increased workload on your heaters of your building that would be required to re warm the building to ambient temperature is high, an air make up is designed for high production of heated air not maintaining a steady state which is typically what a regular shop heater is designed for. To know how long you can run the booth before running out of heated air you calculate the cfm of a booth by taking the width x height x 100 for a cross draft or length x

133 width x 50 for a downdraft, this will give you the approximate cubic feet a minute draw of the booth. You then calculate the cubic feet of your building by multiplying width x height x length. Take the cubic feet of your building and divide by the cfm draw of your spray booth the result is the number of minutes before you would deplete your building of all air. As stated if that number is less than 20 (20 minutes) you should consider an air make up

134 When is an Electrostatic Spray Gun a Good Fit for my Coating Application The primary benefit of electrostatic is its increased production while also reducing paint waste. Electrostatic can be up to 90% efficient in ideal environments. The caveat being ideal environments. Electrostatic utilizes electric current to charge paint particles allowing for them to attract to a target surface. This provides higher transfer efficiency as well as a wrapping effect where paint particles can actually go around a part being painted. However this is under ideal circumstances. What is meant by ideal environments is that the spray process is taking place in a clean, dry, routine, and well grounded environment. Will discuss each part of these fours parts electrostatic spraying in greater detail. Clean - electrostatic requires that the part being painted have a clean surface free from contaminants. If the surface is not properly cleaned the charge on the paint will not properly attract to the part resulting in flawed transfer efficiency. Dry - water is a source of grounding for electrostatic spraying ; which is why it is often difficult to properly get water based coatings to spray well electrostatically. They require special isolation stands for the paint pot along with a myriad of other tweaks. If your part is not dry electric charges will once again not experience the attraction to the part being painted eliminating the benefit of wrapping and improve transfer efficiency. Routine - electrostatic spraying likes objects that lack many nooks or crannies. If a part has a lot of internal or external corners paint will attract to the portions of the part more than others and will result in a poor coating uniformity. This is due to an effect called the faraday cage effect. Additionally electrostatic spraying requires operators understand the tool they use has a high degree of electricity. To safely work with electrostatic spray you need an operator who is able to understand the potential danger of the equipment they hold. They must ensure all objects are grounded so that a spark from the gun doesn t jump and start a fire. They must strive to control paint consistency in regards to paint/solvent mixture, temperature, and humidity conditions. All these variables will allow the electrostatic gun to paint well while reducing risk of electrical spark. Electrostatic guns should also be maintenanced routinely. With a conventional or HVLP gun they are able to be rebuilt easier an electrostatic gun is more expensive at the outstart (it s also way more efficient which allows for relatively quick

135 payback). Additionally the training curve is slightly higher with electrostatic spraying due to additional things to consider, electricity ect. Well grounded - anything that is not grounded can be a source for a spark to jump creating a fire in the worst case scenario. Everything in the booth should be grounded to prevent any electrical arcing and ensure the coating is able to become charged electrically with ease. If you consider these four variables you can determine whether electrostatic would be a good fit for your company. If you have a clean, routine, well grounded, dry environment that you know you will be able to maintain long term electrostatic may be the perfect solution for you.

136 How to Extend the Life of Your Spray Guns Fluid Needle and Nozzle Do you find that you have to replace your fluid needle and/or nozzle more often than you think should be necessary to maintain a quality finish? If this is an issue your dealing with consider the following root causes and potential solutions. 1. Fluid needle position - if the fluid needle is not in the wide open position it places additional strain on your needle and fluid nozzle. The end result is that the noozle and needle wear quicker leading to needing replacement sooner 2. Nozzle and needle material construction - nozzles and needles on many guns come in stainless steel and tungsten carbide. The initial cost of tungsten carbide is quite a bit more, however it will last approximately twice as long as stainless steel components. This is especially important when working with abrasive material such as ceramics. 3. Are the fluid nozzle and needle sized appropriately - Ultimately this point is related to the first point, the needle should be backed out fully during operation when possible. If the needle is adjusted in all the time to achieve the desired pattern and fluid volume necessary evaluate the fluid nozzle and needle combination. You may need to downsize the fluid nozzle and needle to a smaller size so their is less material released from the nozzle, allowing you to maintain the needle in the backed out position. 4. Excessive Fluid Pressure - If your using a fluid gauge to adjust fluid pressure to the gun evaluate the amount of pot pressure you are using. If you require more than lbs of pressure this will cause premature wear of fluid nozzles and needles. The solution is to increase your fluid nozzle to the next size up so you can get the extra production without placing additional stress on your spray gun components. With these four areas in mind you should be able to help deduce and resolve an issue that is causing your spray gun nozzles/ needles to wear out early.

137 Selecting the Right Fluid Nozzle for your Spray Gun Overview of Air Caps and Fluid Nozzles Air Caps provide air to break up a coating, while Fluid Nozzles control the amount of fluid that the spray gun will deliver. The amount of material delivered will vary between gravity fed, suction fed, and pressure fed spray guns. In order of fluid delivered for the same nozzle size from the most fluid delivered to the least the order is as follows. Pressure fed with the most fluid delivered, Gravity Fed second, and suction fed third. The air cap used for each of these guns will differ as well and should be adjusted along with the fluid nozzle for optimum finish results. Suction fed spray guns have specific air caps that they require that are different than those used with a pressure fed or gravity fed spray gun. The CFM rating of the air cap determines how much power the air cap will provide in breaking up a coating. The higher CFM rating an air cap has the heavier and/or higher volume of coating the cap will be able to atomize well. A lower CFM air cap will have a better transfer efficiency and less coating waste along with a softer spray pattern but with a decreased ability to atomize coating well. With this general overview of air caps and fluid nozzles we can move on to determining a good size for your application. Determining the Correct Size of Fluid Nozzle for Your Spray Gun Pressure Fed Spray gun Step 1 - Check your manual for general recommendations of the fluid nozzle size and fluid delivery for each size. This will provide a reference of potential fluid nozzle sizes to consider. Step 2 - With a pressure fed spray gun it is important that you try to keep the fluid pressure applied to the pressure pot less than about 20 PSI. If you have more pressure than that applied it is recommended to try a larger sized fluid nozzle so that the fluid nozzle and needle on the spray gun have lower pressure on them and will last longer. If fluid pressure is greater than 20 PSI and you can Increase the fluid nozzle you should. If you are not receiving enough fluid but the fluid pressure is lower than 20 PSI you can increase the pressure up until 20 PSI or you can adjust to a larger fluid nozzle. For an overview of a pressure fed spray gun and pressure tank you can check out this tutorial to get an idea of how to dial the pressure tank in. Overall, it can take a few tries to determine the best size fluid nozzle for your application. It can also help to talk with a equipment provider to see their recommendation of past sizes.

138 Typically a 1.4 MM fluid nozzle is a good starting point for the majority of coatings and if you need more production or coating increase the fluid nozzle size or if you want finer control of the coating and breakup reduce the nozzle size from a 1.4. Gravity Fed Spray Gun 1. Start with the owners manuals recommendation for different coatings and look at the size range for your particular coating. Essentially the heavier a coating the larger the nozzle will need to be and the lighter a coating the smaller the nozzle will be. Most clear coats are sprayed out of a 1.2 or a 1.4mm nozzle for instance. Stains for wood working are sprayed out of a 1.0 MM or a 1.2 MM. Bases for automotive finish are often sprayed from a 1.6 or 1.4 MM nozzle. 2. Determine how fine a finish you want - A smaller nozzle will allow for a finer finish pattern (as long as the same air cap is being used) this is because more air will be applied to a smaller volume of coating resulting in a finer breakup. If you want a fine finish stick to the smallest fluid nozzle that you can have the material flow through. 3. How thick is the coating? - A heavy Bodied Coating will require a large fluid nozzle and it will often make sense to start with a 1.6 nozzle. If you need more coating bump the nozzle up and if you need less than reduce the nozzle size this will best be done by doing test passes on your product with the nozzle to determine if the coating is being applied to heavy or light. If you cannot get the gravity fed spray gun to deliver enough coating you will want to consider switching to a pressure fed spray gun. Ultimately finding the right nozzle will require trial and error to see how much fluid flow you want. The best technique is to have a sample product to try a few different nozzle sizes to determine what will work best for your particular coating. Suction Fed Spray Guns 1. Again start with the manual. The manual should give you an overview of ideas to consider. Do be aware that with suction fed spray guns they will typically require larger nozzles than gravity or pressure fed spray guns for the same coating. This is because the suction fed spray gun requires air to move across the coating to pull it through the fluid nozzle. So if you have a nozzle that matches from a gravity or pressure fed outfit I would recommend starting with the fluid nozzle one size above the gravity or pressure set up you have been using. 2. Determine how fine a finish you want - The suction fed spray gun will often not be as fine of a finish as a pressure or gravity fed spray gun. If you find your not achieving the finish you want with the suction fed spray gun try reducing the fluid nozzle size or increasing the CFM provided by your Air Cap if this will not work it might be time to consider a gravity or pressure fed spray gun. 3. How Thick is the Coating? - If the coating is highly viscous start with a bit of a larger nozzle like a 1.6 MM fluid nozzle. If more coating is needed you should increase the fluid nozzle size. If less is needed you should consider decreasing the fluid nozzle size. You can also increase or decrease the fluid flow to a certain extent by increasing

139 or decreasing air supplied to the suction fed spray gun but this will also cause increased over spray. If you need help determining a good nozzle for your application we are here to help.

140 Common Paint and Stain Finish Quality Issues and Their Solutions Fish eye Fish eye is much like the appearance that a soap bubble creates on a surface; it creates a distorted oily appearance. Fish eye typically occurs due to oil contaminating your finish. This can be due to maintenance using silicone lubes for your spray equipment, oil in your air line, or oil drifting from nearby work areas. To eliminate fish eye eliminate oil from your air supply, your spray area, and your spray equipment by using the correct lube. Dry spray Dry spray is paint that appears like sandpaper after being applied. This is almost always due to having to high of air pressure or not enough fluid pressure. To fix this issue you should reduce your air pressure to your gun or increase your fluid pressure. You would increase fluid pressure if you wish to have a high level of production or if you want to remain at the same speed of coverage reduce your air pressure. Uneven coating This can occur when the air cap becomes defective or clogged. To determine if the air cap is the source of your troubles spray continuously for a moment and then flip the air cap 180 degrees. You then spray again and observe the pattern, if the uneven pattern changed sides then your air cap needs cleaned or replaced Paint runs Paint runs occur when there is not enough atomization air applied or an operator is not moving fast enough to keep up with the guns fluid output. To resolve this issue the painter needs to check his spray atomization, if it is to much fluid then increase atomization air. However if the atomization looks fine then the painter should consider reducing fluid and air to the gun or moving faster. By understanding why finishes end looking wrong we can correct the underlying issue resulting in better finish quality and more efficient painting.

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142 Reduce Your Coating Costs by Maximizing Transfer Efficiency Transfer efficiency means the amount of paint that leaves from a spray gun and coats the intended product. What ends up not coating the product is referred to as overspray and is wasted paint. Transfer efficiency ranges greatly from 20% up to as high as 90 % with the best conditions and equipment. The benefit of high transfer efficiency is that it will save you on paint cost. Improving transfer efficiency occurs by improving operator skill and equipment selection. This article will focus on equipment selection. Equipment has everything to do with transfer efficiency; different types of equipment have limitations to their maximum attainable efficiency. To understand the different types of spray equipment and their efficiency the following chart will show the varying efficiency of different spray outfits. Spray Gun Type Transfer Efficiency Conventional 30% Airless 35% HVLP when used correctly 65% Air Assist Airless when used correctly 65 % Electrostatic in ideal circumstances 90% While this chart highlights the possibilities of utilizing the right equipment we have to consider other important factors. The equipment is only as efficient as the operator and set up of the equipment. Some examples are that if the operator incorrectly sets his atomization air or fluid pressure he will have reduced efficiency. Similarly if the operator uses the wrong size fluid nozzle and air cap then the spray gun will suffer from reduced efficiency. With electrostatics grounding is crucial to maximize performance. If you do not properly ground the part to be sprayed or the surrounding environment is not grounded correctly paint will seek grounds other than your part resulting in poor transfer efficiency. These are all reasons why it s important to fully understand your equipment so that you benefit from the maximum transfer efficiency possible. In upcoming posts we will dive into further depth of what s important to maximize transfer efficiency within each category of

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144 How you can Ruin the Benefit of HVLP Spray Guns HVLP is a term that means High Volume Low Pressure and refers to how the gun atomizes material. As opposed to a conventional spray gun that uses high volume high pressure of air, HVLP saves on the pressure of air that is used. The benefit to this is that it reduces overspray which means you reduce paint waste by about 50%. The end result is that HVLP helps save money. However, this savings only occurs if you follow the rules of the HVLP gun. All HVLP guns have a maximum air pressure at the horn of the air cap that is considered to be in HVLP spray compliance; this number is typically at most 10 PSI. While the pressure is low, the volume of air is still high, the drop in pressure occurs inside the gun. However if you supply the gun with an excess amount of air you can actually create too much pressure at the horns of the air cap resulting in a gun that is no longer HVLP and no longer more efficient than a conventional spray gun. This is where the most important question comes in. How do you prevent your HVLP gun from starting to spray like a conventional gun? This is where you have to find out the highest air pressure that can be supplied to the gun. This number is usually published on the air cap as well as the literature that came with your spray gun and varies based on air caps. As long as you supply your gun with less than the highest approved amount of air at the air inlet you will maintain the benefits of less paint waste and improved efficiency that is applicable with HVLP. For example if your cap says 24 psi is your maximum air pressure than you should not be feeding that spray gun with more than 24 psi of air at anytime. What if I cannot atomize my coating effectively enough with my air cap on my HVLP gun? The answer is if the cap is not supplying enough air to atomize your coating you have to change the air cap to a larger cap that will atomize your coating. Most spray guns come with a variety of air caps that are specified for different materials. To best size an air cap it is helpful to know the viscosity of your material and the flow rate from the gun.

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146 How to Adjust Spray Guns for Optimum Finishing There are a few ways to control the material and atomization air supplied to a spray gun. However, certain methods allow for greater precision of control while other methods allow for broad based control. Ultimately you will most likely use a combination of methods to control fluid delivery and atomization air to a spray gun, but by thinking through where you coarse and fine tune a spray gun you can achieve better finish qualities. First think about gross adjustments to your spray gun. Primarily this will mean adjusting the amount of fluid delivered (if using a pressure tank) and the atomization air supplied to the gun. If you are using a gravity feed or siphon feed spray gun the gross supply of atomization and fluid delivery is controlled by the same source, the shop air that is fed to the gun. Therefore if you are using a gravity or siphon feed gun your coarse adjustment will be done by adjusting the shop air supplied to the gun at an air regulator. The air regulator will allow you to control the air to the gun from the shop air or compressor which in turn will dictate the amount of fluid and atomization air supplied to the gun. In contrast a pressure fed spray gun will allow you to adjust the fluid delivery and atomization air independently. Typically to get the correct fluid pressure with a pressure feed system you adjust pressure up until a steady flow of material is exiting the tip of the spray gun and is able to travel a few feet in a downward arc. You then would apply the desired amount of atomization air (12 16 psi typically) from the pressure tank as well. All of this can be done at the pressure tank. This second set of controls is the reason why a pressure tank outfit allows for finer control of finishing, with gravity and siphon feed you only control material and air at the gun itself instead of at the pressure tank and gun itself. Once you have adjusted the gross supply of material and air to the gun from a wall regulator or the pressure tank, next you can make your fine adjustments at the spray gun itself. On the back of the spray gun is a fluid needle and spray pattern adjustment. These two adjustments should be considered your fine tuning where you can dial the gun in to the finest width and pattern that you want for your application. The top adjustment will change the width of the spray pattern, the bottom knob adjusts the amount of fluid that is delivered. Typically if you are using a pressure tank you do not want to adjust the fluid needle at the gun, it is better to control the fluid from the pressure tank. By using these ideas in your finishing you can achieve better finishes and often in less time by applying the right amount of material with the right amount of atomization air.

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148 How to Clean a Spray Gun Cleaning a spray gun is critical to maintain its performance and longevity. You should clean your gun after each paint job or change in color/ material, several times a week if your a regular user, and always before being put away for a period of time. Knowing how often to clean the gun is every bit as important as the mechanics of how you clean the gun. The best cleaning method is to use a gun cleaning cabinet as it is fast and efficient eliminating operator time to clean the gun. However, cleaning cabinets are not cheap and so most of us will use there own hands to clean their gun. That is what I intend to talk about. To clean a gun by hand you should first remove the fluid needle, then the air cap, and finally the fluid nozzle. The fluid nozzle is placed on the gun tight and should be removed using a fluid nozzle wrench. A fluid nozzle wrench differs from a regular wrench because it has a thinner fork on each side of the wrench allowing it to grip a fluid nozzle better. After you have completed these steps you then clean the gun using an appropriate cleaner. To clean the gun the best way suitable it is important to use what is recommended by your paint supplier. You then use the cleaner preferably inside a small opening squeeze bottle and turn the gun upside down. Cleaner will pass through the area of the gun where the fluid line was attached. Next you clean the body of the spray gun. Finally you have to clean the spray guns air cap and fluid nozzle. This can be achieved by letting the part soak and/or by using a small soft brush to clean inside the fluid passage. By completing these tasks daily you can help extend the life of your gun as well as maintain quality of finish. photo credit: Costa Rica - Sarchi - Spray Gun not at Rest 2 of 2 via photopin (license)