rule 40 training

RULE 40 TRAINING
© 2010 All Rights Reserved. DeVilbiss Automotive Refinishing, a division of
Inc.
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40 CFR Part 63 Subpart HHHHHH
National Emissions Standard for
Hazardous Air Pollutants: Paint Stripping
and Miscellaneous Surface Coatings
Operations
Presented by:
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Learning Objectives
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List strategies to reduce MeCl usage
Identify spray area requirements
Identify ways to reduce coatings usage
Measure paint viscosity
Select spray equipment
Set up a spray gun
Balance a spray gun pattern
Show proper painting technique
Describe ways to increase transfer efficiencies
Clean and maintain a spray gun
Maintain a spray booth
List the steps for compliance
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Paint Stripping
• 40 CFR Part 63 Subpart HHHHHH is intended to significantly
reduce the amount of hazardous air pollutants (HAP)
introduced into the environment as a result of using strippers
that contain MeCl (Methylene Chloride)
• It does this by requiring that facilities:
– evaluate if the application requires stripping or if the part can be
dry sanded or recoated without the removal of paint
– evaluate whether the paint stripping needs to be done using
stripper containing MeCl
– optimize application conditions when using paint strippers
containing MeCl to reduce evaporation
– practice proper storage and disposal of strippers containing
MeCl by storing in a closed, air tight container
– maintain copies of annual usage of MeCl on site at all times with
proper MSDS sheets
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Spray Area Requirements
• All sprayed coatings must be applied
in a spray booth or prep station
• Spray areas large enough to hold a
complete vehicle must have four
complete sidewalls or curtains and a
roof
• Parts and miscellaneous spraying
must be done in a booth or prep
station with a roof and at least 3
sidewalls or curtains
• The exhaust of the spray booth must
be fitted with filters proven to be 98%
efficient at capturing paint overspray
Example of negative
pressure parts booth
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Eliminating Rework
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Measure coatings correctly
Maintain proper air line filtration
Maintain proper air line regulation
Use proper air hose and fittings
Perform scheduled booth filter
maintenance
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Measuring Viscosity
• Viscosity is a continued resistance to flow
• Paint companies supply specific mixing
information for their materials
• Typically these measurements are shown as
a ratio of volume in their tech sheets. For
example, they may be listed as 3 parts to 1
with 10% reduction or 3:1:10%
• To compensate for temperature changes and
the differences in viscosity of specific toners,
manufacturers will usually list a specific
viscosity in their technical data sheets
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Measuring Viscosity
• Commonly used viscosity measuring devices
– Zahn #2 - #3 cups are commonly used when
measuring viscosity of US refinish materials
– DIN 4 cups are commonly used when measuring
viscosity of European refinish materials
– They come in two different styles, “standard” or in a
dip cup versions
– Standard cups are filled until the meniscus (concave
upper surface of the liquid) disappears
– Dip cups are completely submerged
– With a standard cup, measure the time from when the
fluid is released from the bottom of the orifice
– With a dip cup, measure from then it is pulled out of
the liquid until the first break in the stream
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Measuring Viscosity –
Step by Step
• Ensure that the cup is clean
• Completely immerse viscosity
cup
• Begin timing when the top of
the viscosity cup breaks the
edge of the paint surface until
the first major break in the fluid
stream
• With some Din 4 dip cups the
time must be doubled because
they are half the size of a
standard Din 4. Know what
size cup you are using
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Compressed Air Filtration
and Regulation
• Clean, dry, oil-free air is required when
spraying either waterborne or solvent
materials
• Even the slightest amount of
contamination can cause coating
imperfections
• Point of use filter / dryer / regulators
provide the cleanest, driest air possible
and therefore a superior finish
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Contaminants and Filters
• Water – centrifugal filter
• Dirt, rust and pipe scale – centrifugal filter (5
micron filter)
• Oil and oil vapor – coalescent filter (.01
micron filter)
• Odor – charcoal filter (.003 PPM filter)
• Humidity – desiccant filter (-40°F dew Point)
• Air Control – regulator (>50cfm capacity)
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Centrifugal / Coalescent /
Charcoal / Dual Regulation
Model # 130526
• Used for painting in areas
of low humidity,
particularly with
waterborne basecoats
• Utilizes an inlet shut off
valve for maintenance
• Bowls are easily removed
for maintenance
• Manual drains
• Contains 2 self-relieving
high volume regulators
for air to blower stand /
spray gun
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Centrifugal / Coalescent
/ Desiccant Dryer
Order# 130522
• For painting in areas of high
humidity
• Filters remove water, dirt and
oil down to .01 micron
• Desiccant removes humidity
down to a dew point of -40 F
• Includes an inlet shut off valve
for maintenance
• Bowls are easily removed for
maintenance
• Desiccant in a bag makes
changing simple
• Self relieving high volume
regulator
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Laminar and Turbulent Air
Flow
Laminar Air
Turbulent Air
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Sources of Pressure
Loss
Air Hose
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Air Hose Pressure Loss
• Hose ID has the greatest effect on pressure loss
• As length increases, pressure drop increases
• A rough tube can cause up to a 50% increase in
pressure drop (i.e. poor quality or worn out)
Pressure Loss with 100 psi Inlet Pressure
35' Hose
50' Hose
15 CFM 25 CFM 15 CFM 25 CFM
1/4" ID 35 psi 87 psi 50 psi
*
5/16" ID 12.6 psi 31.5 psi 18 psi 45 psi
3/8" ID 4.2 psi 10.5 psi 6 psi
15 psi
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Proper Hose and Fitting
Set Up
• Hose mounted
directly to the
regulator
• Hose ID of 3/8”
• Hose length of 35’ or
as short as possible
• Only one quick
disconnect at the gun
• Digital gauge for
accuracy
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Select a Spray Gun
• Under EPA 40 CFR Part 63 subpart HHHHHH
all coatings must be applied with an HVLP,
electrostatic, airless, air assisted airless or a
spray gun demonstrated to be equal in transfer
efficiency to HVLP
• HVLP and air spray equipment demonstrated to
deliver HVLP or better transfer efficiencies
produce the highest quality automotive finishes
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Select a Spray Gun
• HVLP = (High Volume Low Pressure)
– What does HVLP mean?
• Sprays at 10psi or less at the air cap at a given
inlet pressure. The 10psi or less pressure is an
internal pressure measurement taken at the center
of the cap and at the air horn
– Identification
• Gun must be marked with “HVLP” and the proper
inlet pressure that achieves 10psi at the air cap
– Compliance paperwork for painter
• None
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Identification for HVLP
Marked on Gun Handle
Marked on Air Cap
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Select a Spray Gun
• Compliant Spray Gun
– What does compliant mean
• Spray gun must deliver transfer efficiencies equal to or
better than HVLP at a given inlet pressure
– Identification
• Spray gun must have the inlet pressure marked on it
that achieves transfer efficiencies equal to or better
than HVLP
– Compliance paperwork for painter
• For spray guns that do not meet the designation of
HVLP, you must have documentation from the spray
gun manufacturer that states that the gun has transfer
efficiency equal to or better than HVLP
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Compliance Letter
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Correct Gun Setup
(HA-5867) 35’ Air Hose / High Flow Fitting / ¼”(F)NPS
Digital Gauge
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Standardizing Gun Set
Ups
• Improving work quality and productivity while
controlling material usage involves developing
procedures that produce high quality work
consistently and efficiently
• A standardized set up is extremely important
when setting up and balancing a spray gun in
order to deliver optimal results in a quick
repeatable manner
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Paint Company Information
• DeVilbiss works with paint companies to update
spray gun charts with correct fluid tip and air cap
selections
• These recommendations help maintain finish
quality while minimizing material usage. Fluid tip
recommendations control fluid flow through the
gun. Air cap and inlet pressures ensure proper
atomization of the specific materials being sprayed
• This information can be found in the technical data
sheets for your paint manufacturers or can be
found on the DeVilbiss website at
www.autorefinishdevilbiss.com
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Gun Adjustments
• Pattern Control Knob
– Controls the height of
the pattern
– Balances the pattern
• Fluid Adjustment Knob
– Controls the amount of
fluid that comes out of
the gun
• Air adjustment valve
– Controls amount of air
entering the spray gun
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Initial Gun Set Up
• The pattern adjustment knob should be adjusted
out as far as it will go or positioned where it will
deliver the largest pattern possible
• Adjust the fluid control knob out until a full trigger
pull can easily be achieved. Then adjust the
fluid adjustment knob back in while holding a full
trigger pull until the needle starts to put pressure
on the trigger
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Digital Gauge
• Determining the
correct inlet pressure
is critical for
atomization and color
match
• Waterborne
orientation coats are
often sprayed at 1214psi which can’t
easily be measured
with dial type gauges
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Split Pattern –
Too Much Air Pressure
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How to adjust a split pattern
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Perform a static and dynamic
spray pattern
– A static pattern is a quick burst or
the peanut pattern shown on the
left. This is to determine droplet
size and evenness of pattern
– A dynamic pattern is a quick pass
to see distribution on combined
droplets
Check to see if droplets at the
edge of the pattern are suitable
and even in size
If so, adjust pattern control knob
clockwise until pattern balances
If droplets are too small, reduce
air pressure until desired droplet
size is achieved and then turn
pattern in until it balances
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Narrow Pattern –
Air Pressure Too Low
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How to adjust a narrow pattern
• Perform a static and
dynamic spray pattern
• Adjust pattern knob
all the way out
• Increase air pressure
until pattern widens to
an acceptable width
and droplet size
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Balanced Pattern –
Correct Air Pressure
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Correct Air Pressure, Balanced
Pattern
• Perform a static and
dynamic spray pattern
• Static pattern is
evenly shaped with a
consistent droplet
sizing at the edge of
the pattern
• Dynamic pattern
delivers even material
distribution
throughout the sweep
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Keep Track of Gun
Adjustments
• Once the gun has been correctly adjusted for air
pressure, pattern size, and fluid flow, record the
gun settings for that particular material
• Record air pressure
• Count how many turns out the pattern control
knob is by adjusting it clockwise all the way in
until it stops
• Count how many turns out the fluid control knob
is by adjusting it clockwise all the way in until it
stops
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Spray Gun SOPs
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Spray Distance
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Spray Distance
• Spray distance should be 5-8” away when
spraying an automobile. Distances can be
slightly greater when spraying fleet or some
waterborne finishes
• Spraying closer than 5” tends to drive in-flight
solvents into the finish causing hazing and
solvent pop
• Spraying farther away than 8” tends to cause dry
spray and orange peel
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Gun Targeting and
Movement
• Wrist is flexible
• Gun is held
perpendicular to the
target
• Gun is moved parallel
to the target
• Trigger is released at
the end of each
stroke
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Arcing
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Wrist not flexible
Arcing motion
Uneven application of coatings
Varying gun distance leads to
uneven texture
• Arcing at the end of each stroke
causes excessive overspray
• Any time the spray direction deviates
from perpendicular to the target,
transfer efficiencies and finish
qualities diminish
• Arcing is a main cause of haloing along the blend line. As the spray
gun arcs, the target distance increases which causes paint to reach
the surface too dry. This causes mottling of metallics and creates
texture that will show up differently under clearcoats
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Tilting
• Tilting of the spray gun causes
uneven film build
• This leads to striping and uneven
texture
• In extreme cases, dry spray and
sags can occur in the same panel
• Even slight tilting can increase the
number of coats required to achieve
hiding and deliver an acceptable
finish
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Proper Overlap
• 50% overlap is the minimum overlap possible to achieve uniform film
thickness
• Because it is hard to be that robotic, typically overlap will need to be
between 50 and 75% depending on how difficult the color is to spray
• 50% overlap would be spraying a pass across the target and then
starting the top of the next pass in the middle of the pattern created by
the first pass. 75% overlap would be to start the second pass ¼ down
from the top of first pass
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• Exceeding 75% leads to excessive film build
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Controlling Overspray
• Anytime the pressure is lowered or the pattern is
turned in, material usage is typically reduced
• Primers that are going to be sanded can be
sprayed at lower pressures with narrower
patterns than topcoats to help reduce overspray
• Sealers can also be sprayed with less energy
and narrower patterns to control paint usage
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Clean a Spray Gun
• Guns should be thoroughly cleaned after
each use. Parts should be checked for wear
and replaced as needed
• 40 CFR Part 63, Subpart HHHHHH states
that all gun cleaning should be done in a
closed gun washer or by cleaning the
disassembled gun body by hand. This rule
allows solvent to be flushed through the
fluid passages of the gun without atomizing
it
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Enclosed Gun Washers
• Whether cleaning the gun by hand or using an enclosed
gun washer, the gun should be periodically broken down
to ensure that no deposits of paint are left in the gun
body
• A plug should be attached to the air inlet of the gun
before it is placed in an enclosed gun washer
• After cleaning guns in an enclosed gun washer, guns
should be removed, dried and lubricated
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Enclosed Gun Washers
• Some cleaning solutions can become corrosive
over a period of time and alter the appearance
and performance of the spray gun
• Separate waste streams are required for solvent
and waterborne; therefore, separate gun
washers for waterborne and solvent are required
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Cleaning by Hand
• When cleaning by hand, disposable cup systems are
highly advantageous
• Remove disposable cup and run solvent through the fluid
passages of the gun
• Remove the air cap and brush with a soft cleaning brush.
Run small brushes through the annular hole in the air
cap and wipe dry
• DeVilbiss Spray Gun Cleaning Kit (#192212) includes
these brushes
• Do not mix solvent and water waste streams
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Maintenance
Needle Packing Spreader Valve
Air Cap
Fluid
Adjustment
Screw
Fluid
Tip
Fluid Needle
Air Valve
• Regularly
lubricate the
needle packing,
air valve,
adjusting screws,
trigger stud, and
air cap threads
Air Adjustment Valve
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Troubleshooting
• The most common spray equipment problems
involve either the fluid tip or the air cap
• Soak air caps in quality thinner or acetone.
Brush the front and back of the air cap with
cleaning brushes and run brushes through the
annular hole in the air cap
• Performing pattern checks on a regular basis is
recommended
• Problems with uneven patterns can easily be
diagnosed by simply rotating the air cap
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Troubleshooting
• Horn holes plugged
• Obstruction on top or
bottom of fluid tip
• Air cap or fluid tip seat
dirty
• Left or right side horn
holes plugged
• Dirt on left or right side
of fluid tip
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Troubleshooting
• Pattern adjustment knob turned
in too far
• Material flow exceeds the
capability of the cap
• Atomization pressure too low
• Material too thick
• Fluid adjustment knob set too far in
• Atomization pressure too high
• Pattern adjustment knob set too
far out for the material being
sprayed
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Troubleshooting
• Loose or damaged fluid
tip/seat
• Material too low
• Obstruction in fluid
passage
• Dry or loose needle
packing
• Air vent in cup lid clogged
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Spray Booth Maintenance
• Clean the booth regularly and keep it clear of unnecessary
items such as shelves and towel dispensers that can collect
dust
• Clean walls and light covers regularly. Paint the booth walls
as needed for high visibility
• Do not perform prep work in a spray booth
• Door seals should be checked periodically to make sure they
are sealing
• Waterborne dryer heads should be covered when not in use
to keep them clean
• Intake filters should be changed according to booth
manufacturer’s specifications
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Spray Booth Maintenance
• Final filters should be 10 micron or less
– Anything larger than 10 micron will show up in a paint job
• Paint arrestor filters are required to be 98% efficient by EPA
40 CFR Part 63, Subpart HHHHHH. Filter manufacturer
specifications have to be kept on file to meet this requirement
• If you have a booth maintenance contract, make sure that the
filters match your filter specification to remain in compliance
• In order to deliver high throughput and get clean jobs, it is
important to establish a filter change-out schedule
• Readings from a manometer or water column pressure gauge
should be used to establish filter change frequency
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$20
www.autorefinishdevilbiss.com
800.445.3988
© 2010
All rights reserved.
A-2982 Litho in USA. 04/10
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RULE40
TRAINING
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