Troubleshooting Guide
Got problems? We can help
Polychem powders are generally easy to apply using all types of powder application that are available today.
Occasionally you may encounter problems, so we have created a Troubleshooting guide which you can refer to.
General points on applying Polychem powder:
- Application variables influence the appearance of a finish to a greater degree
- Generally, Polychem powders should be applied at a higher mil. thickness, especially the river textured and lower gloss finishes
- Certain shades will not hide as well when the gloss is lower, especially whites, yellows, light grays, and off whites
If you experience any problems, please refer to the useful troubleshooting guide below. If you are still stuck, then please call us at 940-6654-8892 or email us at info@polychemcoatings.com and we’ll do our best to assist you.
Probable Cause
Solution
Excess film thickness
Reduce film thickness by decreasing spray time and/or powder flow air pressure.
Grounding
Confirm all your equipment is properly grounded
Spray Distance
Recommended spray distance is approximately 10-14 inches away from your product, distance may change depending on your equipment settings and part configuration.
KV Settings
Improve the ground connections and/or lower the KV settings.
Probable Cause
Solution
Overbaking
Reduce film thickness by decreasing spray time and/or powder flow air pressure.
Improper oven exhaust
Check exhaust fans
Oven temperature too high
Adjust oven temperature accordingly
Gas ovens: quality of gas
Ensure coatings are suitable for gas ovens. Consult coatings manufacturer.
Probable Cause
Solution
Poor Grounding
Check the ground and all contact areas are free of powder build-up and other insulating materials.
Voltage is too low or interrupted
Increase the voltage or check for broken electrodes.
Conveying air pressure too high
Adjust the equipment air setting to its optimum.
Wrong hose material
Consult your equipment manufacturer for a recommended hose.
Probable Cause
Solution
Cure Schedule
Increase oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.
Film thickness
Reduce film thickness by decreasing spray time and/or air pressure.
Poor substrate
Ensure parts are properly cleaned and pre-treatment s in good working order.
Wrong hose material
Consult your equipment manufacturer for a recommended hose.
Probable Cause
Solution
Same color differs between suppliers
Purchase each color from the same supplier.
Probable Cause
Solution
Contamination
Make sure the gun, hopper and spray booth is completely cleaned and that the powder was stored correctly.
Over cured
Decrease oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.
Probable Cause
Solution
No fluidizing air
Check the air supply or change hose for one with larger inside diameter.
Obstructed membrane
Adjust the seating of the membrane and check for plugged pores.
Packed or moist powder
Extend fluidization with dry clean and pol free air or manually loosen powder. Sieving powder may be necessary.
Probable Cause
Solution
Variation in the cure cycles
Maintain the temperature at a consistent level.
Variation of the distance between powder gun and object
Maintain consistent distance while spraying.
Probable Cause
Solution
Shortcut due to powder build up in the gun and hoses
Consult the equipment manufacturer and use adaptors suitable for metallic application (electrodes outside).
Probable Cause
Solution
Substrate heat up time
Adjust oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.
Improper storage
Make sure that the powder has been stored in the proper environment. Storage in high temperature or humidity can ruin powder.
Film thickness
Verify that product is applied at manufacturers’ recommended film thickness. Film thickness may vary depending on the product, powder and equipment that is used.
Conveyor line is interrupted variance in substrate wall
Avoid line slow or shut down optimize cure cycle.
Probable Cause
Solution
Conveying air pressure too high
Adjust air pressure accordingly.
Incorrect hose material
Consult equipment manufacturer for correct nozzle materials.
Moisture in air supply
Clean air supply and ensure free of oil and dirt.
Worn parts or pumps
Consult equipment manufacturer.
Probable Cause
Solution
Under cured
Increase oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.
Incorrect hose material
Consult equipment manufacturer for correct nozzle materials.
Probable Cause
Solution
Film thickness too high
Adjust equipment accordingly
Film build too low
Increase film thickness.
Cure temperature
Adjust the temperature up/down accordingly. Check heat-up rate of oven and temperature recordings
Probable Cause
Solution
Film thickness
Verify that product is applied at manufacturers’ recommended film thickness. Film thickness may vary depending on the product, powder and equipment that is used.
Pre-treatment
Ensure parts are properly cleaned and pre-treatment is in good working order. Consult with your pre-treatment supplier for recommended pre-treatment procedures.
Under cured
Increase oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.
Probable Cause
Solution
KV settings
Limit the micro amps, lower voltage.
Spray distance
Recommended spray distance is approximately 10-14 inches away from your product, distance may change depending on your equipment settings and part configuration.
Poor ground
Confirm that all your equipment is properly grounded.
Probable Cause
Solution
Voltage too high
Adjust gun voltage accordingly
Gun nozzle type
Select appropriate nozzle to ensure spray patter is not too wide/narrow.
Powder delivery air too high
Adjust accordingly
Faraday cage effect
Use Tribo/airstatic processed powder and spray equipment
Probable Cause
Solution
Distance between gun and part is too close
Move the gun further away from the part.
Powder is delivered inconsistently
Adjust the equipment/air setting to its optimum.
Irregular voltage
Check the entire system (from voltage source to electrode) to ensure continuous electrical charge.
Probable Cause
Solution
Contamination
Make sure the gun, hopper and spray booth is completely cleaned and that the powder was stored correctly.
Contamination in air line
Ensure that the air is clean and dry. Check oil absorption unit. If there is a consistent problem, install a filter.
Pretreatment
Ensure that parts are properly cleaned and that pre-treatment is in good working order. Consult with your pre-treatment supplier for recommended pre-treatment procedures.
Probable Cause
Solution
Back ionization due to inferior ground (insulation)
Avoid too high of a film thickness on the first base coat; check for clean hooks.
Too high voltage
Lower gun KV settings.
Poor grounding
Check ground from conveyor rail to part
Distance gun tip to part too close
Increase distance of gun tip to part
Probable Cause
Solution
Cure temperature
Reduce oven temperature and/or time accordingly.
Film thickness is too high
Adjust equipment accordingly
Probable Cause
Solution
IR-oven: temperature too high
Increase line speed, or reduce the temperature.
Probable Cause
Solution
Incompatibility of two powder types
Use only one batch at a time and avoid mixing.
Probable Cause
Solution
Under cured
Increase oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.
Probable Cause
Solution
Cure cycle too short and/or substrate temperature too low
Check cycles and substrate temperature.
Probable Cause
Solution
Improper storage – temperature or humidity too high, or shelf life expired
Screen and sieve powder prior to spraying. Consult powder supplier.
Probable Cause
Solution
Film thickness variation
Verify that product is applied at manufacturers’ recommended film thickness. Film thickness may vary depending on the product, powder and equipment that is used.
Oven exhaust
Confirm that the exhaust system is functioning correctly.
Over cured
Decrease oven temperature and/or time, coating may begin yellowing if over cured. Verify that the object itself reaches the correct cure temperature for the correct time.
Probable Cause
Solution
Film thickness
Verify that product is applied at manufacturers’ recommended film thickness. Film thickness may vary depending on the product, powder and equipment that is used.
Poor substrate
Porous substrates such as blasted, cast, or galvanized parts may require a pre-bake over the recommended cure schedule.
Probable Cause
Solution
Outgassing of the substrate materials
Degassing by pre-heating or use Out Gassing Forgiving (OGF) materials. Available through Polychem
Film thickness too high
Apply less coating
Powder too moist
Check air dryer
Contamination
Make sure the gun, hopper and spray booth are completely cleaned and that the powder was stored correctly.
Probable Cause
Solution
Film thickness (too thin)
Verify that product is applied at manufacturers’ recommended film thickness. Film thickness may vary depending on the product, powder and equipment that is used.
Pre-treatment
Ensure parts are properly cleaned and pre-treatment is in good working order. Consult with your pre-treatment supplier for recommended pre-treatment procedures.
Under cured
Increase oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.
Probable Cause
Solution
Under cured
Increase oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.
Probable Cause
Solution
Film thickness
Verify that product is applied at manufacturers’ recommended film thickness. Film thickness may vary depending on the product, powder and equipment that is used.
Pre-treatment
Ensure parts are properly cleaned and pre-treatment is in good working order. Consult with your pre-treatment supplier for recommended pre-treatment procedures.
Under cured
Increase oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.
Probable Cause
Solution
Too high of a film thickness is causing insulation
Recoat top coat with tribo/airstatic equipment. If E-static equipment is used, lower the voltage.
Poor grounding
Check for clean hooks
Probable Cause
Solution
Hose may be too long or kinked
Reduce hose length and ensure consistent air pressure.
Inconsistent powder supply
Insufficient or irregular air pressure Check for plugged pores or compacted powder in lines.
Probable Cause
Solution
Contamination
Make sure the gun, hopper and spray booth is completely cleaned and that the powder was stored correctly.