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Fluid Air

Powder Systems

Home / Tech Tips / Powder Systems
What is the buzzing sound on the GEMA EZ unit when you trigger it on? What can I do to fix it?
How do control unit connections work?

With a flow meter tool. Click here to troubleshoot

How do you tell when your hose insert is worn out?
What can I do if the powder is not adhering to the part I am coating?

Make sure that the part is properly grounded. The maximum resistance between the part and the earth ground should not exceed 1 megohm. Make sure the gun is producing high voltage. If the problem continues, try new or fresh powder.

How do I resolve inconsistent gun deliveries?

Check your fluidization. The powder should appear to be “simmering”. Make sure that all o-rings and pump inserts are in good shape and that powder hoses are clean and clear. Confirm that the air supply is feeding the system with consistent and correct pressure (normally 100 to 120 psi). Check for possible blockage in check valves located on gun pumps.

What causes UV shutdowns?

Most UV shutdowns are caused by powder build-up on part fixtures or hangers, which causes arcing between the fixtures and the parts. The detection system sees this arcing and shuts down the system. Shutdowns can also be caused by non-grounded objects in the spray area, or by external sources, including operations near the booth.

My fluidization is inconsistent. Why is this happening?

Possible causes include an incorrect reclaim to virgin powder ratio, inconsistent air supply to the hopper, and changes in the environment, like humidity. All of these factors can influence fluidization. Due to a shift in particle size, new or virgin powder is easier to fluidize than powder that has been reclaimed. When new powder is first sprayed, more of the larger particles are transferred to the parts than the smaller ones, which is why reclaim powder has a smaller particle size distribution than virgin powder. The objective is to maintain a ratio that fluidizes and charges efficiently.

What is the correct temperature and humidity for a powder application room?

The ideal temperature for powder application is between 60 and 80 degrees Fahrenheit. Humidity should be kept between 40% – 60%.

How do I lower the reject rate?

Here are some pointers that may help lower your reject rate:

  • Powder Chemistry – Make sure you follow the powder supplier’s recommendations. If powder is not cured for the specified time and temperature, you may experience rejects.
  • Pretreatment – If there is oil, water or other debris on a part, there is a strong likelihood you will see defects after curing.
  • Grounding – Without proper grounding, a good transfer of powder from gun to part cannot be achieved.  Clean hangers and check grounding regularly.
  • Training – Your personnel should be proficient at using the various techniques required to get adequate coverage on a variety of part geometries.  This will prevent the orange peel effect, fatty edges, and other defects.
  • Gun Placement – On automatic systems, guns that are not properly placed can cause parts to e coated too lightly or too heavily in spots.
  • Maintenance – Simple maintenance issues such as worn nozzles and pump inserts can cause a wide variety of defects.  A regular regimen of cleaning and maintenance can greatly improve the life and performance of your equipment