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Common Powder Coating Gun Problems and Solutions

March 22, 2017

There's no pleasure to be found in troubleshooting. It all feels a bit like hitting your head against a brick wall. Granted, powder coating technology has been adopted as an industry-wide finishing solution, but there's still equipment idiosyncrasies to deal with, yes, even here. On the subject of powder coating guns, several issues crop up from time-to-time. Here's a look at the more common problems you may experience with these handheld sprayers.

Uneven Discharge

The gun spits out the powder, workpiece coverage is uneven, and it's back to square one. What's gone wrong in this scenario? If the air supply in the gun hose is irregular, the flowing powder burps, spits, and surges. A regulated discharge relies on a properly controlled air source. Check for kinks in the hose before calling out a technician to overhaul the compressor. Better yet, start at the spray zone by ensuring the discharge nozzle at the front of the gun is tight and free of blockage.

Poor Delivery

Complex geometrical profiles are easy to fully coat when the equipment is set just right, but this happy circumstance can desert you when you need it most. If the coating won't penetrate holes and cover fine surface details, try adjusting the voltage setting on the gun. Extend the circuit inspection to the ground connector. Alternatively, turn up the air delivery setting. If neither of these corrective actions yields positive results, consider connecting a barrel extension to the gun so that the powder reaches every nook and cranny.

Workpiece Repulsion Effect

Curiously, the powder isn't just refusing to adhere to the part, it's actively being repelled. This back ionisation condition disrupts the distribution of the electrostatic charge. Again, this is a circuit issue. Check the ground, turn down the gun voltage, and consider pulling the gun back from the work area. You could be too close to the part. A gun nozzle-to-part surface distance of 20-cm to 25-cm is adequate for most powder coating work.

Common sense works well here, but, should that sixth sense fail, put on your troubleshooting cap. Overcoverage problems and under coverage issues are related. The circuit is likely poorly setup, so turn everything to the off position. Is the electrical ground configured? Perhaps the kV (kilovolt) rating of the gun has shifted. Reset the equipment, adjust the power setting, the air discharge level, and finish by clearing the gun nozzle. As for ionisation problems and powder "burps," practise a good gun control method while making sure the air is dry, clog-free, and unhindered.

GP Industries Pty Ltd

Head Office

1 Regal Court,
Vermont South VIC 3133

Phone: (03) 9802 1355

Fax: (03) 9802 6027

Email: gp_ind@bigpond.com

Factory

Factory G,
20 Burgess Road,
Bayswater North VIC 3153

Phone: (03) 9761 7676

Fax: (03) 9761 7671

Email: gpfactory@bigpond.com

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