Problems in generating compressed air

  • Compressor too small
    Compressed air volume is not sufficient and pressure drops.
    Continuous compressor operation heats compressed air and causes oil and condensation to increase.
    Continuous operation at high temperatures shortens compressor lifetime.
  • Compressor too old
    Compressor performance is too low and as a result not profitable.
    The compressor consumes a lot of oil that may be fed to compressed air lines together with high abrasion.
    Compressed air is sucked in from a wet, dusty area.
  • High amount of condensation
    A high concentration of condensation in compressed air shortens filter lifetime.
    Consequences of missing or inadequate filtration:
    - Shorter lifetime of compressed air tools
    - Bad paint jobs with dust and water
     

Please find additional details concerning the remedy for problems in the compressed air supply in the Compressed Air Advisor.


       
Problems in the compressed air line and filter installation
 

  • Air reserve tank too small
    Pressure drops as soon as other air tools are used
    Compressed air is too warm causing condensation to rise to a level where oil and water separation is no longer ensured.
  • Insufficient or missing condensation discharger in the separator sump
    Condensation is drawn as “water” into the compressed air line causing immediate contamination.
    Water may overflow the oil / water separator causing condensation to enter into the compressed air line.
    Too much dirt from the compressed air line may affect the function of automatic condensation valves and similar devices.
  • The compressed air line inner diameter is too small compared to its length
    Pressure drop leads to high-energy loss.
    When tapping compressed air, the pressure drops and may lead to non-satisfactory painting.
  • Compressed air lines without an incline, “swan neck” (see illustration) and/or condensation discharge at the end of the air line
    Condensation is drawn into the valves.
    Condensation remains inside the pipes causing scale and corrosion.
  • Insufficient filtration and separation
    Condensation and unfiltered dirt shorten the lifetime of compressed air driven tools and cause dust and water specks on the painted surface.

Please find additional details concerning the remedy for problems in the compressed air supply in the Compressed Air Advisor.

       
  
     

Problems with spray gun control adjustments

  • Incorrect nozzle size / Damaged nozzle set
    To achieve optimum finishes, the correct nozzle set must be selected according to the material ViscosityMaterial viscosity is the time (in seconds) it takes the material to completely flow out of a standardized container. There are different measuring methods available. Please find the corresponding chart attached. X».
    Clogged or damaged air cap holes affect the spray pattern.
  • Uneven fan pattern causes bad surface finishes with “runs” etc.
    Air pressure too high or too low.
    The nozzle set was not fine tuned by the manufacturer. At SATA every spray gun and separate nozzle set is checked by hand and fine tuned.
  • The fan pattern has too much mist
    The material is applied too “dry” with uneven distribution.
    Insufficient atomization and air pressure combined with heavy orange peel.
    ! Always adjust the best air pressure when triggering the spray gun.
  • Wrong combination of spray ViscosityMaterial viscosity is the time (in seconds) it takes the material to completely flow out of a standardized container. There are different measuring methods available. Please find the corresponding chart attached. X»
    ViscosityMaterial viscosity is the time (in seconds) it takes the material to completely flow out of a standardized container. There are different measuring methods available. Please find the corresponding chart attached. X» too high: causes insufficient atomization.
    ViscosityMaterial viscosity is the time (in seconds) it takes the material to completely flow out of a standardized container. There are different measuring methods available. Please find the corresponding chart attached. X» too low: causes runs.
  • Improper selection of distance to target
    Spray distance too close: too much material causes runs.
    Spray distance too far: too much overspray bounce-back.
    Spray distance too far: fan collapses, non-homogeneous spray pattern.
    Spray distance too far: danger of metallic mottling.
  • Incorrect spray gun air micrometer adjustment
    In spite of correct pressure setting at the regulator, Air Cap PressureAir cap pressure is air pressure inside the air cap of the spray gun. Dieser darf bei HVLP Pistolen nicht über 10 psi (0,7 bar) liegen, zum Nachweis sind für einige Modelle Prüfluftkappen erhältlich mit denen nachgemessen werden kann.X» is incorrect leading to color match problems. During “normal’ painting, always leave the built-in air micrometer fully open.
  • Incorrect fan control adjustment
    The fan width too narrow or too wide for the best working speed.
  • Material flow setting turned back
    Material flow setting may be too low for the best paint job.