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Troubleshooting
Poor Electrostatic Wrap Troubleshooting
Problem Cause Solution
The system is holding voltage but
there is poor electrostatic wrap on
The distance between the gun and
workpiece is incorrect.
Adjust the spraying distance to 8 to
12 inches (203 to 305 mm).
the part being sprayed
The parts are poorly grounded. Clean the workpiece hangers; check
for proper grounding on the conveyor
or track.
Booth exhaust velocity is too high. Reduce the exhaust velocity within
the code limits.
The atomizing air pressure is too
high.
Reduce the atomizing air pressure.
The fluid pressure is too high. Reduce the fluid pressure.
The fluid viscosity is not right for
electrostatic spray.
Check with the supplier for proper
fluid viscosity for electrostatic spray.
Gun Operation Troubleshooting
Problem Cause Solution
Fluid leakage from the fluid pack-
ing area
The fluid rod packings or fluid rod are
worn.
Replace the packings or rod; see
page 33.
The packing nut is loose Tighten the packing nut; see page 33.
Air leakage from the front of the
gun
The air valve is not seating properly. Clean and service the air valve; see
page 36.
The air valve o-ring is sticking. Lubricate the o-ring; see page 36.
Fluid leakage from the front of the
The fluid rod is worn or damaged. Replace the fluid rod; see page 33.
gun
The fluid seat is worn. Replace the fluid nozzle and/or elec-
trode needle; see pages 30 to 32.
The fluid packing is too tight. Lubricate and adjust the packing nut;
see page 33.
The resistor stud is loose. Tighten the resistor stud; see page
30.
The fluid nozzle is loose. Tighten the fluid nozzle; see page 30.
The resistor stud o-ring is damaged. Replace the o-ring; see page 30.
“Orange Peel” finish
The air pressure is insufficient for
good atomization.
Increase the air cap air pressure by
opening the atomizing air valve more
or increasing the gun air inlet pres-
sure; use the least air pressure need-
ed for good results.
The fluid is poorly mixed or filtered. Remix or refilter the fluid.
An improper thinner is being used. Use the proper thinner.