HVLP TRAINING MANUAL High Volume Low Pressure Equipment Form No.
Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Spraying Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 When to use HVLP Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 How does HVLP Work? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 How to Acquaint the Painter with HVLP . . . .
Introduction The contractor market for HVLP spray systems is the fastest-growing market segment in the spray equipment industry. As you’ll soon realize, HVLP sprayers represent a tremendous opportunity to help painters become more competitive and profitable. Used primarily for finishing work, HVLP sprayers work hand-in-hand with airless equipment to help contractors reduce the time and material necessary to complete a job. The key is minimized overspray.
Spraying Methods HVLP Two types of HVLP systems dominate the painting contractor market: portable turbines and direct hook-up guns. The two systems use completely different air sources, but atomize material in similar manners. Portable Turbine Most commonly found in the painting contractor market for portable applications, this type of HVLP system uses a centrifugal blower motor as the air source. Direct Hook-up Guns Direct hook-up guns require an air compressor as the air source.
Spraying Methods Air-Assisted Airless Electrostatic Spray Air-assisted airless sprayers offer fine finish capabilities combined with a medium production rate. Air-assisted technology uses a combination of airless and air spray. Fluid pressure ranges from 700 to 900 PSI, with air intermixed at 15 to 30 PSI. The systems typically are found in stationary and portable fine finish production applications. Transfer efficiency for air-assisted airless ranges from 40 to 65%.
How Does HVLP Work? A pressure vessel (1-quart cup, 2-quart cup, or pressure pot) supplies paint to the gun, where a large amount of low pressure air intersects with the paint stream breaking the paint into small particles. This process is called atomization. Air diverted to atomize paint Low pressure stream of paint Air diverted to pressurize the cup High volume of air in from turbine Pressure causes paint to flow to spray gun Since the pressures are much lower, the atomized paint has less bounceback.
How to Acquaint the Painter with HVLP The most effective way to show the advantages of HVLP equipment is to demonstrate it. Contractors will see how they can save labor hours, use less paint and increase profits. HVLP sprayers are not for every painter. Be certain they are involved with the appropriate finishing application. Then match the correct unit size and tip size to the type of materials they use.
HVLP System Components As with most sprayers, three distinct components make up an HVLP system: air source, air hose, and HVLP spray gun. There are several variations of these components depending upon the manufacturer. We will deal primarily with Sherwin-Williams CAPspray equipment. Air Source The air source is the heart of the system. It provides the CFM and PSI required to atomize coatings.
HVLP System Components Please note that while air flow (CFM) and pressure (PSI) are both important in determining the turbine‘s ability to atomize coatings, pressure is the key. All manufacturers rate their turbines in the range of 50-170 CFM. Whether the turbine produces 50 or 170 CFM, it will still have enough air flow to support the gun. The gun only uses about 25 CFM. Therefore, CFM as a measure of performance can be misleading. Pressure determines the velocity of the air moving through the air cap.
HVLP System Components Maxum I HVLP Spray Gun (continued) HVLP guns differ from conventional air spray guns in two main areas: One difference is the size of the internal air ports. Conventional gun air port openings are approximately 1/4''. HVLP guns need more air and use openings 5/8'' in size. That makes the air ports more than 6 times as large as those in conventional guns. Keep in mind that HVLP atomizes with a high volume of air and low pressure.
Maxum I HVLP Spray Gun Adjustments Air Control Valve To produce the highest-quality finish possible, the spray gun requires the proper air and material adjustments. You control the air flow with the air control valve, located at the rear of the gun. Note the notch that is cast into the control knob on the valve. Air flow is at its fullest when the knob is set at the 12:00 position. Rotating the valve 180° either direction cuts off the air.
Maxum I Air Cap Adjustments Air Cap CAPspray‘s exclusively designed guided air cap makes it virtually impossible for the painting contractor to misalign. This translates to better spray pattern control. The air cap determines the spray pattern. It is crucial the air cap remains clean and free of dried paint. Spray Pattern The Sherwin-Williams CAPspray HVLP gun offers a choice of three spray patterns: horizontal flat, vertical flat and round.
Spray Techniques Spraying Techniques Position the spray gun perpendicular to and 1 to 8 inches from the spray surface. Spray parallel to the surface and use controlled, smooth passes at an even speed. Start by applying a thin coat of material on the first pass and allow it to tac before applying a second, slightly heavier coat. Correct How to Make the Correct Pass Incorrect When spraying, trigger the spray gun before starting your pass, and release trigger before stopping the pass.
Spray Techniques Spraying Large Areas Spray a long panel or wall in sections. Use horizontal or vertical strokes. Keep stroke length to 3 feet. Spraying a longer pattern may cause uneven coverage and excessive overspray. Overlap each section by 4 inches. Narrow panels are best sprayed using vertical strokes to help prevent too much overlapping.
Spray Techniques Spraying Square Posts or Steel Adjust the material adjustment knob to the desired spray width. Spray two adjacent surfaces at the same time. Grills and Wire Fences Hold the gun at a sharp angle. Deflect the paint passing through the grill or fence with a flat surface. This will help coat the other side. Spraying Round Work For cylinders up to three feet high or wide, spray vertically. For larger cylinders, such as storage tanks, spray horizontally.
Choosing a Projector Set Projector Set The projector set determines what materials and viscosities can be sprayed from the gun. A larger projector set has a larger nozzle opening, allowing you to spray thicker, heavier materials. A projector set consists of a needle assembly, fluid nozzle and air cap. Needle Assembly Fluid Nozzle Air Cap The Maxum I spray gun comes standard with a #3 guided projector set.
Projector Set Recommendation Chart Material Percent Smallest Unit Reduction Recommended Projector Set Recommended Projector Set Orifice Size(in.) Pro Mar 200 10-15% 9100 4 to 5 .070 to .086 Pro Mar 400 10-15% 9100 4 to 5 .070 to .086 Super Paint 5-15% 8100 3 to 4 .051 to .070 Classic 99 5-15% 9100 3 to 4 .051 to .070 Ceiling Paint 5-10% 5100 3 to 4 .051 to .070 DTM Water Base Acrylic 0-5% 5100 3 to 4 .051 to .070 Chem Lack 2-4% 9100 3 to 4 .051 to .
Cleaning Your Equipment Spray Gun It is important to clean your spray gun thoroughly after each use. 1. Empty the spray material from cup. 2. Pour a small amount of the appropriate solvent in the cup and attach the cup to the spray gun. 3. Shake and spray the gun in a well-ventilated area. Back-flushing of the system is not necessary, so do not restrict the nozzle when cleaning. 4. Repeat the steps above until the solvent appears clear. 5.
HVLP Spray Equipment Troubleshooting Problem Cause Little or no material out of nozzle. Out of paint. Air cap screwed clockwise too far. Check valve plugged. Material viscosity too heavy. Nozzle plugged. Cup or pot lid is loose. Pressure Pot System: Fluid hose clogged. Regulator not adjusted. Pot gasket worn. Pick-up tube bottomed out on gallon can. No air pressure in pot. Paint leaking from front of gun. Needle or nozzle worn. Needle sticking. Improper needle or nozzle size. Loose nozzle.
HVLP Spray Equipment/Finish Troubleshooting Problem Cause Solution Filter warning light on. Air filters clogged. Clean or replace filters. No trigger pull. Material adjustment knob too tight. Turn counter-clockwise. Unit has no power. Blown fuse. Check and replace fuse. Cup doesn't retain power. Worn cup gasket. Cup ears bent. Replace. Straighten (do not over-tighten). Excessive arcing/sparking. Worn turbine brushes. Damaged commutator. Replace brushes. Replace turbine. Orange peel.
Sherwin-Williams CAPspray 5100 SMIS No. 176-5064 A compact unit for mid-size jobs, the 5100 offers the painter a great deal of versatility in the type of work, yet is compact and completely portable. Increased performance allows the contractor to spray stains, sealers, lacquers, oil-based and finish-grade latex. A rugged, two-stage by-pass turbine delivers ample air pressure and volume to handle higher viscosities better than any comparable unit.
Sherwin-Williams CAPspray 8100 SMIS No. 176-5072 The 8100 is ideal for jobs that require continuous spraying and the ability to handle difficult-to-atomize materials. It sprays stains, clear coats, lacquers, oil-based epoxies and multi-color coatings. Also applies most water-reducible coatings, including waterborne lacquer and finish-grade latex. The large or small contractor taking a wide variety of jobs will benefit from the 8100.
Sherwin-Williams CAPspray 9100 SMIS No. 176-5080 The 9100 is the most powerful portable turbine system available. It has an exclusive, 4-stage tangential turbine that produces the kind of performance needed to spray continuously and to atomize coatings with a minimal amount of reduction. Sprays stains, clear coats, lacquers, oil-base, and multi-color coatings. Also applies most water-reducible coatings, including waterborne lacquer and finish-grade latex.
Sherwin-Williams Portable Cart SMIS No. 176-5098 The Portable Cart is compatible with the 5100, 8100 or 9100 for complete mobility around job sites. Built-in air compressor and 2 1/2 -gallon pressure pot allows fast, continuous spraying for larger jobs. Higher fluid PSI results in faster application rates with the pressure pot.
Mounting Models 5100, 8100 or 9100 Mounting a Turbine on Your Cart Your cart mounting hardware includes two spring clips, four screws and a mounting plate. Spring Clip Screw Mounting Plate If your turbine looks like this: you will need to use the mounting plate only. Attaching the Mounting Plate 1. Remove the two screws and foot pads from underneath the turbine exhaust pipe side of the turbine. Turbine Exhaust Pipe Foot Pads Screws 2.
Sherwin-Williams CAPspray 3100 The 3100 is designed to be used in conjunction with any HVLP unit. It consists of a compressor, two-quart cup and connecting hoses. A 30-foot air hose provides air from the compressor to the two-quart cup, and a 6-foot fluid hose feeds material from the cup to the gun. Air to the gun is supplied by the host HVLP turbine. The 3100 doubles the reservoir capacity of standard HVLP guns and reduces arm and hand fatigue by removing the reservoir from the gun.
Assistance/Warranty When a Customer Needs Help For ordering, application, technical and service information, Sherwin-Williams store personnel can speak directly to SprayTech technical specialists by calling toll free: 1-800-U-CALL-SW (1-800-822-5579) Contractor customers with questions concerning applications, technical or service information can call toll free: 1-800-292-4637 Tough Customer™ Guarantee The Tough Customer™ Guarantee is an exclusive in the spray equipment industry.
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