Toubleshooting
Powder Supply During Application
Trouble
Non-symmetrical powder cloud
Powder Application Problems
Trouble
Poor charging - inadequate powder film
thickness or poor coverage
Possible Causes
Worn gun parts
Impact fusion build-up
Delivery air too low
Hoses, powder pumps or guns blocked
with powder
Reciprocator speed too fast
Possible Causes
High voltage source not providing enough
KV at charging electrode
Poor ground
Powder delivery rate is too high
Excessive moisture in powder booth air
Powder too fine
Powder type or formula
Powder delivery air too high; powder
blowing by part
Solution
Replace parts as required
Check gun parts as required
Check air supply; increase air for powder
feed
Clean hoses, pumps and guns
Adjust gun cycle time
Solution
a) Check if high voltage source is on;
systematically check continuity from
voltage source to electrode, including
cable, resistors and fuses
b) Replace missing or broken electrode
c) Clean electrode insulated by powder
build-up or impact fusion
Check ground from conveyor rail (or rub
bar when used) through hanger to part. All
contact areas must be free of powder build
up, heavy grease and other insulating
materials
Reduce powder delivery rate until material
is adequately charged
Moisture in humid air will tend to dissipate
the charge on the powder particles; control
the humidity in the powder spray area
a) Maintain consistent blend of virgin and
recycled powder
b) Check particle size of powder; contact
your powder supplies
Some powder formulations charge better
than others and some formulas are
designed for thin film application; contact
your powder supplier
Turn down air setting or move gun position
farther away from part
Powder Application Problems (cont'd)
Trouble Possible Causes Solution

Poor penetration - powder will not coat Powder delivery too low Turn up powder delivery air settings
Faraday cage area (holes, grooves,
channels, inside corners & recesses)

Poor ground Check ground; refer to 'Poor Ground'

above

Incorrect powder spray pattern a) Adjust powder spray pattern

b) Try alternative nozzle selections

Voltage too high Turn voltage setting down so that surfaces

closer to gun do not repel powder from
corners

Powder delivery velocity too high Turn air setting down so powder air stream
does not blow powder into corners

Poor gun placement Adjust gun position so powder cloud has a

direct path to recessed area

Back ionization - powder layers are Voltage too high Turn down voltage settings
repelled from part

Gun positioned too close to part Change gun placement farther away from
part

Poor ground Check ground; refer to 'Poor Ground'

above

Excessively heavy powder build up Refer to 'Powder delivery rate is too high'
above
Powder Application Problems (cont'd)
Trouble
Powder feed surging or spitting -
interrupted powder feed
Possible Causes
Insufficient air pressure or volume
Hoses kinked, flattened or too long
Hoses, powder pumps or suction tubes
Incorrect powder delivery
Incorrect feeder hopper fluidizing
Solution
Check air supply; determine if air supply
piping to equipment is large enough;
enough air volume must be provided to that
air pressure to powder feed does not drop
Check powder feed hose routing &
condition; refer to 'Obstruction of powder
delivery system' in 'Powder Supply
Problems' section
a) Clean hoses, powder pumps & guns
b) Check air supply for moisture
c) Check powder delivery settings
d) Check coating area relative humidity &
temperature
e) Check powder delivery system for
vacuum leaks
a) Check powder delivery settings
b) For low powder delivery rates, increase
powder transport air function settings
c) Replace powder hose with smaller
diameter hose
a) Adjust fluidization air pressure
b) Check porous fluidizing membrane for
clogging or defects
c) Refer to 'Powder fluidization/air blowing
holes through powder surface' on 'Powder
Supply Problems' section
Booth and Recovery Equipment Problems
Trouble
Part surface contamination
Poor powder containment; inadequate air
flow through spray booth
Cross contamination of recycled powder
Possible Causes
Powder or contamination falling in spray
booth from conveyor or hangers
Contamination from parts entering spray
booth
Contamination from plant air circulated
through spray booth
Contamination from compressed air supply Check compressed air supply system
Powder sieve screen torn, missing
Inoperable powder sieve
Primary filter media binding
Final filters clogged
Use of compressed air both booth
cleandown
Improper powder gun placement /
alignment
Room draughts leading to powder drifting
from booth
Blocked airflow
Inadequate blower operation
Inadequate booth/recovery equipment
cleaning
Solution
Clean conveyor regularly for continuously
before it enters spray booth; strip hangers
as needed
Check cleaning and pre-treatment
equipment for proper operation; ensure
proper part drying before part enters spray
booth
Isolate spray booth area; preferably
enclosed in a room with filtered humidity
controlled air; maintain positive pressure in
coating room; inspect nearby operations as
possible contamination sources; correct as
necessary
Replace sieve screen
Repair sieve or sieve control circuitry or
replace if necessary
a) Clean or replace filter media as required
b) Check ambient air humidity in coating
area
c) Check filter media air pulse operation
d) Check for moisture / oil in compressed
air supply
Check primary filter media for powder
leakage; service, repair or replace as
needed
Refer to operations manual for proper
cleaning procedures
Correct as necessary, position guns away
from openings
Map airflow in powder booth area; minimize
draughts to eliminate powder drift
a) Check air volume control damper
adjustment
b) Check fire safety device for proper
operation
Check for proper operation
Clean equipment per equipment supplier
recommendations
Booth and Recovery Equipment Problems (cont'd)
Trouble Possible Causes Solution

Booth turbulence High powder containment air velocity Contact equipment supplier

Powder recovery percentage below Insufficient air volume/velocity Refer to 'Poor powder containment -
equipment specification Inadequate air flow through spray booth'

Poor system seals Verify and correct any air leaks

Too high percentage of powder fines Contact your powder and equipment
suppliers
Powder Supply Problems
Trouble Possible Causes Solution

Poor blowing out of hopper Fluidization air pressure too high Adjust air regulator to lower pressure to
fluid bed

Insufficient hopper ventilation a) Check hopper vent for plugging

b) Check vent assist device for obstruction
and proper air supply

No air percolating through powder surface Insufficient air pressure Check hopper fluidization air supply;
increase air pressure as required

Plugged membrane Check membrane for plugged pores or oily

air supply

Obstructed membrane Check bottom of hopper for obstructions

Compacted powder on membrane Manually loosen powder and fluidize well

with clean, dry air

Poor fluidization / air blowing large holes Powder level too low Add powder until hopper is filled to proper
through powder surface level

Packed or moist powder a) Manually loosen powder and fluidize well

with clean dry air
b) Check compressed air and booth air for
humidity or oil content
c) Powder sieving may be required

Obstructed membrane Check bottom of hopper for obstructions

Plugged or broken membrane a) Check membrane for plugged pores or

oil contaminated air supply, cracks or holes

b) Check for proper seating of membrane /

leaking around edges

Particle size a) Maintain consistent blend of virgin &

recycled powder
b) Check particle size of powder in hopper

Insufficient fluidizing characteristics of Contact your powder supplier

powder
Powder Supply Problems (cont'd)
Trouble Possible Causes Solution

Poor fluidization / air blowing large holes Powder level too low Add powder until hopper is filled to proper
through powder surface level

Air pressure too high a) Reduce powder hose length

b) Turn down air settings on pumps & guns

Moisture in air supply Check air supply for clean, dry, oil-free air

Composition of powder fed hoses Check hoses; contact your equipment

supplier

Worn powder pumps and worn parts Replace all worn parts

Powder particle size a) Maintain consistent blend of virgin &

recycled powder
b) Check particle size of powder in hopper;
contact your powder supplier

Powder type of formula Some powder types are more susceptible

to impact fusion; contact your powder
supplier

Kinked or flattened hoses a) Avoid sharp bends and restrictions in the

hose; protect hoses from external abrasion
& abuse
b) Replace if permanently deformed

Powder hose too long or has too many Reduce powder hose length, modify hose
sharp bends runs

Insufficient powder feed Powder not fluidizing Refer to 'No air percolating through powder
surface' and 'poor fluidization/air blowing
large holes through powder surface'

Obstruction of powder delivery system a) Check suction tubes, powder pumps,

hose and gun
b) Check air supply; adjust settings to
pumps and guns
c) Check powder supply for contamination

Powder hose too long or has too many Reduce powder hose length; modify hose
sharp bends runs

Low air pressure Check air supply; adjust air settings to

pump and guns
Film Properties Problems
Trouble Possible Causes Solution

Color - Off shade Stoving time too long Adjust line speed

Oven temperature too high Decrease oven temperature

Foul oven air Check gas supply, burners and venting

Bare edges / areas - pinholing and gassing Poor cleaning, metal preparation or dry-off Check pre-treatment equipment, dry-off
through coating surface oven and part drainage

Film aspect - texture pattern or metallic Guns too close or distant from component Adjust distance
effect incorrect

Powder delivery too high Adjust

Film thickness too high or low Adjust

Poor mechanicals - poor impact resistance, Undercured Increase oven temperature

poor flexibility
Increase dwell time in oven

Poor cleaning or pre-treatment Check pre-treatment equipment and

chemicals

Film thickness too high Reduce film thickness by adjusting

application equipment

Change in substrate thickness or type Check with substrate supplier

Film Properties Problems (cont'd)
Trouble Possible Causes Solution

Adhesion - poor adhesion Poor cleaning or pre-treatment Check pre-treatment equipment and
chemicals

Change in substrate thickness or type Check with substrate supplier

Undercured Increase oven temperature

Increase dwell time in oven

Chemical resistance - poor chemical Undercured Increase oven temperature

resistance
Increase dwell time in oven

Surface hardness - poor pencil hardness, Undercured Increase oven temperature

poor abrasion resistance
Increase dwell time in oven

Overcured Reduce oven temperature

Poor flow - too much orange peel Film thickness too low / high Increase / decrease film thickness by
adjusting application equipment

Oven temperature too low Set oven to correct temperature

Heat up rate too slow Modify oven baffling heat rate at front of
oven
Film Properties Problems (cont'd)
Trouble Possible Causes Solution

Gloss too low - too low for high gloss Incompatible powder contamination Clean application equipment before
powder changing powders

Micropinholing from gassing Check component for porosity

Check component for moisture
Check powder for moisture from reclaim or
compressed air
Check film thickness, coating too thick

Contamination in powder Reclaim in-line sieve torn Repair sieve or replace if necessary

Contamination from plant air circulated Isolate and preferably enclose spray booth
through spray booth area

Film thickness - inconsistent film thickness Guns positioned correctly Check and reposition guns

Reciprocators not matched to line speed Adjust line speed

Adjust reciprocator stroke

Air speed in booth disturbing spray pattern Consult your equipment supplier

Defective spray equipment Consult your equipment supplier

Changing Colors During Powder Application
In any powder coating operation using multiple colors or powder types there is risk of contamination occurring during the change-
over between powders. However, it is possible to minimize this risk using well ordered cleaning procedures.

When performing a color change, the cleaning operation should follow the same route as the powder does when spraying. So,
cleaning should begin with the hopper followed by the pumps, hoses and guns which in turn are followed by a thorough cleaning of
the booth enclosure.

Clean down is completed by cleaning or changing the recovery system. All cleaning operations using compressed air should be
performed inside the booth to ensure that the powder is contained, thus reducing the risk of airborne contamination.

The length of time that color changing takes can vary widely depending on the plant type and configuration. For operations which
require many color changes to be performed often and swiftly, it may be necessary to have multiple booths. Alternatively, most
major equipment suppliers now offer booth with polyethylene sheeting walls which are replaced with each color change to eliminate
cleaning of the booth.

Cyclone recovery systems are for the most part self-cleaning and require little maintenance.

In the case of cartridge systems, it is necessary to color dedicate cartridge collector units. If many colors are required, it may be
impractical to use a large number of units.