why my spraying pressure is less than 100bar
Pressure below 100 bar is not automatically a fault. Some coating and low-pressure-tip combinations work at lower pressure. for example our green color spray tip could atomize the paint at 100bar without problem, but the black spray tip is a high pressure tip which need at least 140bar to get a good result. So if the black tip has a pressure of 100bar, the painting finish will be not good, you could see two tails at the both side of the atomization. it means the problem exists when the sprayer cannot produce the application pressure and spray pattern required by the selected coating and tip.
Compare spraying pressure with static pressure
A gauge reading with the gun closed is not the same as pressure while spraying. Note both readings and observe whether the pattern deteriorates when you trigger the gun. Pressure at the machine can also differ from pressure at the gun because the hose and filters create resistance. Never exceed the lowest pressure rating of any system component.
Work through these checks in order
| Observation | Likely area to check |
|---|---|
| Pressure drops with a large or old tip | Excessive tip demand or tip wear. Change a new tip and try again |
| Slow delivery with a clean, correct tip | Strainers, filters, material viscosity and hose restrictions. So change / clean the filter and try again |
| Bubbles or interrupted flow during priming | Low material level, suction fittings or seals. Pour more paint and try again, or try with water to see if the problem keep same. |
| Return flow continues in spray mode | Prime/spray valve, where this is not normal for the model. Try to set to Prime version for 1 minute, and set to SPRAY version again to check |
| Machine cannot hold pressure or cycles unusually | Leaks, valves, seals, diaphragm or piston v-packings wear |
1. Confirm the coating and tip combination
Check the coating technical data sheet and the sprayer’s supported tip size. Compare with a new, approved tip of the correct size. A worn tip passes more material, so a previously workable setup may lose pressure. Do not use a fixed number of square metres as a universal replacement interval.
2. Remove supply restrictions
After pressure relief and power isolation, inspect the inlet strainer and the specified pump and gun filters. Confirm the hose diameter and length suit the material. A thicker coating, colder material or added hose can change performance. Thin only if the coating manufacturer permits it and only with the specified product and amount.
3. Inspect for leaks safely
Stop immediately if there is a fluid leak, damaged hose or loose pressure-rated connection. Never search for a leak with your hand or tighten a fitting under pressure. Inspect suction seals separately: an inward air leak may not leave wet paint outside the joint.
4. Escalate internal checks to service
Inlet and outlet valve wear, damaged packings, diaphragm problems or control faults need model-specific diagnosis. Do not remove a valve, push its spring or open a pump while pressure remains. The earlier article’s live-valve tests should not be used as a general troubleshooting procedure.
Review the airless spray tip range and record the tip code, coating, hose arrangement and pressure with the trigger open and closed before requesting assistance.
