SmartArc
PPG Electric Arc Gun
Spraying Tables


 (US) Inc., Westbury, NY 11590

Document 57969 Iss. a

Revision due to ECN 11759

SPRAYING TABLES AND GENERAL COST DATA

HOW TO USE THE TABLES

The spraying tables on the following pages list the information needed to set up and operate the
Sulzer Metco SmartArcTM PPG Electric Arc Gun. The tables give the basic data for figuring accurate costs and also approximate figures which are helpful in making rough estimates of cost and
coating weights.

HOW TO COMPUTE SPRAYED AREA

When estimating surface area, an allowance for loss at the edges must be made. A good rule is to
add one inch (25.4 mm) to each dimension where there is an edge. When estimating the cost of
spraying a shaft, add two inches (50.8 mm) to the length - one inch at each end.

Area Formula
Circumference of a circle

= D

Area of a circle

= R2

Area of a cylinder

= DL

Area of sphere

= D2

Area of a triangle

= bh

Area of a parallelogram

= bh

Area (lateral) of a cone

= r (r2 + h2)1/2

Where = 3.14, R = radius, D = diameter, b = base, L = length, h = height, r = radius of base.

CALCULATING COSTS
An important factor to take into account when calculating the cost of a coating is the normal variation in thickness between the thinnest and the thickest spot. The extent of this variation depends on
the job and the manner in which it is sprayed. For ordinary corrosion-resistant coatings, use average thickness of the coating in calculating cost. However, if minimum thickness is specified, be
sure to spray the coating thick enough so that no spot will be thinner than the specified minimum.
If this thickness is not known from experience, spray a test area to determine average thickness
required.

When spraying shafts less than four inches (101.6 mm) in diameter, overspray becomes a factor in
cost. For production jobs involving such parts, tests to establish overspray losses are recommended.

EXAMPLE (U.S. System)

Let us assume you want to calculate the cost of spraying a shaft. The shaft is 45.5 inches long x
4.75 inches in diameter. You want to build up the diameter 0.150" (a coating thickness of 0.075")
with METCOLOY #2. You have 14 ga METCOLOY #2 in stock and intend to spray it at 200 amps. Complete steps 1 through 6 as follows:

1. Compute the area to be sprayed.

To compensate for edge loss, add 2" to the length of the shaft, making the length
45.5 + 2 = 47.5
Area = DL = 3.14 x 4.75 x 47.5 = 708 square inches (approx)
2. Calculate volume of coating. Coating volume = area x coating thickness = 708 x 0.075 = 53
cubic inches (approx).
3. Calculate volume deposited per hour. Coverage (spraying table) x 144 in2/ft2 x 0.001 in = 510
(144) (0.001) = 73.44 in3/hr.
4. Calculate time required.
Time = Coating volume divided by the volume deposited per hour = 5373.44 = 0.72 hours to
do job.
5. Calculate weight of wire required.
Weight = time required multiplied by spray rate shown in spraying table = 0.72 x 18 = 13 lbs
(approx).
6. Calculate air and electricity used.
Air = time required multiplied by consumption in cubic feet per min (see note 3)
= 0.72 x 41= 30 cubic feet (approx.) or 1800 cubic feet per hour.
Electricity= time required multiplied by Hourly Consumption in KW Input (spraying table) =
0.72 x 6 = 4.3 KWH (approx.)
7. Calculate total cost of spraying.
Total cost = wire cost plus electricity cost plus air cost plus labor cost. Wire cost = cost per
pound x weight used. Electricity cost = cost per KWH x KWH used. Air cost = cost per cubic
foot x cubic feet used. Labor cost = labor cost per hour x time required.
Note that the above information relates only to the cost of SPRAYING. The cost of the job also
includes:
cost of surface preparation before spraying.
cost of machining or other finishing needed after spraying.
Where machining or grinding of the coating is required, allow for the material to be removed when

calculating the thickness of coating to be sprayed.

EXAMPLE (Metric System)

Let us assume you want to calculate the cost of spraying a shaft. The shaft is 1150 mm long x 120
mm in diameter. You want to build up the diameter 4 mm (a coating thickness of 2 mm or 0.2 cm)
with METCOLOY #2. You have 14 ga METCOLOY #2 in stock and intend to spray it at 200
amps. Complete steps 1 through 6 as follows:
1. Compute the area to be sprayed. To compensate for edge loss, add 50 mm to the length of the
shaft, making the length 1150 + 50 = 1200 mm.
Area = DL = 3.14 x 120 x 1200 = 452,160 mm 2 or 4522 cm2 (approx.)
2. Calculate volume of coating.
Coating volume = area x coating thickness = 4522 x 0.2 = 904 cm 3 (approx.)
3. Calculate volume deposited per hour = Coverage (spraying table) x 1 x 104 cm2/m2 x (0.1 mm)
x 0.1 cm/mm = 1210 cm3
4. Calculate time required.
Hours = Coating volume divided by the volume deposited per hour = 9041210 = 0.74 hours to
do job.
5. Calculate weight of wire required.
Weight = time required multiplied by spray rate shown in the spraying table = 0.74 x 8.2 = 6.1
kg (approx)
6. Calculate air and electricity used.
Air = time required multiplied by consumption in m3 per min = 0.74 x 1.2
= 0.88 m3, or 52.8 m3 per hour (approx).
Electricity = time required multiplied by Hourly Consumption in KWH (spraying table).
Electricity = 0.74 x 6 = 4.4 KW
7. Calculate total cost of spraying.
Total cost = wire cost plus electricity cost plus air cost plus labor cost.
Wire cost = cost per kg x kg used.
Electricity cost = cost per KWH x KWH used.
Air cost = cost per m3 x m3 used.
Labor cost = labor cost per hour x time required.

Note that the above information relates only to the cost of SPRAYING. The cost of the
job also includes:
cost of surface preparation before spraying.
cost of machining or other finishing needed after spraying.

Where machining or grinding of the coating is required, allow for the material to be
removed when calculating the thickness of coating to be sprayed.

SPRAYING TABLES

Spraying Table - SmartArc Gun

FINE AIR CAP (Metric System)
Sulzer Metco
Wire

Air Pressure
bar

(NOTES 4, 5)

Primary

Operating
Parameters

Hourly
Consumption

Clamping

Amps

Volts
(NOTE 1)

kg Wire

kW Input
(Approx)

1.7-2.4
1.7-2.4

200
350

28-32
28-32

8.2
16.4

6,000
10,500

kg Wire
Required
per m2/0.1mm
deposited

Coverage
(NOTE 6)
m2/h/0.1mm

0.73
0.73

12.10
24.20

(NOTES 2, 3)
Metcoloy #2

2.4-4.2
2.4

Metcoloy #5

2.4-4.2

1.7-2.4

200

26-28

9.1

5,500

0.87

10.48

SM 8400

2.4-4.2
2.4-4.2

1.7-2.4
1.7-2.4

200
350

26-28
26-28

9.1
15.9

5,500
9,500

0.99
0.99

9.09
15.90

SM 8276

2.1

1.7-2.4

200

30-34

9.1

6,500

0.99

9.08

Sprabronze
AA

2.4
2.4

1.7-2.4
1.7-2.4

200
350

28-32
28-32

6.8
13.6

6,000
10,500

0.93
0.93

7.33
14.67

Aluminum
AW,14 ga.

2.4-4.2
2.4-4.2

1.0-1.4
1.0-1.4

200
300

26-28
26-28

4.5
7.3

5,500
8,000

0.42
0.42

10.86
17.37

Aluminum AW,
11 ga.

2.4
2.1

1.0-1.4
1.0-1.4

200
350

34-36
34-36

5.0
8.6

7,000
12,250

0.35
0.35

14.11
24.38

Zinc AW, 14
ga.

2.4

1.4-2.1

200

21-23

17.7

4,500

0.99

17.70

Zinc AW, 11
ga.

3.1
3.1

1.4-2.1
1.4-2.1

200
350

21-23
21-23

18.1
31.7

4,500
7,700

1.09
0.92

16.64
34.42

Sprababbitt A

2.4

1.4-2.1

200

22-26

24.9

5,000

1.05

23.78

Copper

2.4

1.7-2.4

200

26-30

11.3

5,500

0.93

12.22

Spraying Table - SmartArc Gun

FINE AIR CAP (English System)
Air Pressure
psi

Sulzer Metco
Wire

Operating
Parameters

Hourly
Consumption

(NOTES 4, 5)

lb Wire
Required
per ft2/0.001
in. deposited

ft2/h/0.001 in

0.04
0.04

510.0
1,020.0

Coverage
(NOTE 6)

Primary
(NOTES 2, 3)

Clamping

Amps

Volts
(NOTE 1)

lb
Wire

kW Input
(Approx)

Metcoloy #2

35-60
35

25-35
25-35

200
350

28-32
28-32

18
36

6,000
10,500

Metcoloy #5

35-60

25-35

200

26-28

20

5,500

0.05

443.52

SM 8400

35-60
35-60

25-35
25-35

200
350

26-28
26-28

20
35

5,500
9,500

0.05
0.05

384.62
673.08

SM 8276

30

25-35

200

30-34

20

6,500

0.05

384.38

Sprabronze
AA

35
35

25-35
25-35

200
350

28-32
28-32

15
30

6,000
10,500

0.05
0.05

310.46
620.92

Aluminum
AW,14 ga.

35-60
35-60

15-20
15-20

200
300

26-28
26-28

10
16

5,500
8,000

0.02
0.02

459.59
735.34

Aluminum
AW, 11 ga.

35
30

15-20
15-20

200
350

34-36
34-36

11
19

7,000
12,250

0.02
0.02

597.46
1,031.98

Zinc AW,
14 ga.

35

20-30

200

21-23

39

4,500

0.05

749.54

Zinc AW,
11 ga.

45
45

20-30
20-30

200
350

21-23
21-23

40
70

4,500
7,700

0.06
0.05

704.70
1,457.44

Sprababbitt
A

35

20-30

200

22-26

55

5,000

0.06

1,006.71

Copper

35

25-35

200

26-30

25

5,500

0.05

517.44

FINE AIR CAP NOTE

1. The voltage range shown under Operating Parameters should be adjusted to provide a
smooth and stable arc. If the voltage is set too high the spray pattern may be poor causing
large particles to be deposited on the spray surface. If the voltage is set too low, particularly
with the hard wires, the arc may be erratic and cause a popping sound. Under this condition,
raise the arc voltage until the popping stops and then increase one to two morevolts. (Voltage is recorded at the gun).
2. Pressure range indicated (35-60 psi) gives you a range of coating properties. Using higher
air pressures may improve coating properties, i.e., increase hardness, finer surface finish
and increased density. However, the oxide content of the coating will also increase as will
the stress level within the coating.
3. Air consumption for fine air cap at 35 psi (2.4 bar) is 41 CFM (1160 liter/min) and at 60 psi
(4.2 bar) is 70 CFM (1980 liter/min).
4. Standard Spray Distance 4''- 6'' (101.6 mm - 152.4 mm).
5. Unit is packaged with standard hardware to spray 14 ga. hard wires. For other wires, see
Arc Wire Setup Hardware Table, this section.
6. Wire required and coverage figures are based on spraying large, flat surfaces with little
overspray loss.
CAUTION
Be Sure Proper Contact Tips, Contact Tubes, Wire
Guides, And Drive Rolls Are Installed In Gun And
That Proper Lower Drive Roll Is Installed In
Controller. Refer To Arc Wire Setup Hardware Table,
This Section.
NOTE
For further material coating characteristic information
refer to appropriate technical bulletin.

Spraying Table - SmartArc Gun

FAN AIR CAP (Metric System)
Sulzer Metco
Wire
(NOTES 3, 4)

Air Pressure
bar

Operating
Parameters

Hourly
Consumption

kg Wire
Required
per m2/0.1mm
deposited

Coverage
(NOTE 6)
m2/h/0.1mm

Primary
(NOTE 2)

Secondary

Clamping

Amps

Volts
(NOTE 1)

kg Wire

kW Input
(Approx)

Metcoloy #2

2.4

1.7

1.7-2.4

200

28-32

8.2

6,000

0.73

12.10

Metcoloy #5

2.4

1.7

1.7-2.4

200

26-28

9.1

5,500

0.87

10.48

SM 8400

2.4

1.7

1.7-2.4

200

26-28

9.1

5,500

0.99

9.09

SM 8276

2.4

1.7

1.7-2.4

200

30-34

9.1

6,500

1.07

8.47

Sprabronze AA

2.4

1.7

1.7-2.4

200

28-32

6.8

6,000

0.93

7.33

Aluminum
AW,14 ga.

2.4

1.4

1.0-1.4

200

26-28

4.5

5,500

0.46

9.87

Aluminum AW,
11 ga.

1.7

1.4

1.0-1.4

200

34-36

5.0

7,000

0.38

13.03

Zinc AW,
14 ga.

2.4

1.7

1.4-2.1

200

21-23

17.7

4,500

0.99

17.70

Zinc AW,
11 ga.

2.4

1.7

1.4-2.1

200

21-23

18.1

4,500

1.09

16.64

Copper

2.4

1.7

1.7-2.4

200

26-30

11.3

5,500

0.99

11.35

Spraying Table - SmartArc Gun

FAN AIR CAP (English System)
Sulzer Metco
Wire
(NOTES 3, 4)

Air Pressure
psi

Operating
Parameters

Hourly
Consumption

lb Wire
Required
per ft2/0.001
in. deposited

Coverage
(NOTE 6)
ft2/h/0.001
in.

Primary
(NOTES 2)

Secondary

Clamping

Amps

Volts
(NOTE 1)

lb
Wire

kW Input
(Approx)

Metcoloy #2

35

25

25-35

200

28-32

18

6,000

0.04

510.00

Metcoloy #5

35

25

25-35

200

26-28

20

5,500

0.05

443.52

SM 8400

35

25

25-35

200

26-28

20

5,500

0.05

384.62

SM 8276

35

25

25-35

200

30-34

20

6,500

0.06

358.76

Sprabronze
AA

35

25

25-35

200

28-32

15

6,000

0.05

310.46

Aluminum
AW,
14 ga.

35

20

15-20

200

26-28

10

5,500

0.02

417.81

Aluminum
AW,
11 ga.

25

20

15-20

200

34-36

11

7,000

0.02

551.50

Zinc AW,
14 ga.

35

25

20-30

200

21-23

39

4,500

0.05

749.54

Zinc AW,
11 ga.

35

25

20-30

200

21-23

40

4,500

0.06

704.70

Copper

35

25

25-35

200

26-30

25

5,500

0.05

480.48

FAN AIR CAP NOTE

1. The voltage range shown under Operating Parameters should be adjusted to provide a
smooth and stable arc. If the voltage is set too high, the spray pattern may be poor causing
large particles to be deposited on the spray surface. If the voltage is set too low, particularly
with the hard wires, the arc may be erratic and cause a popping sound. Under this condition,
raise the arc voltage until the popping stops; then increase one to two more volts. (The indicated voltage is the voltage monitored at the gun.)
2. Fan air cap provides the capability of producing a wide spray pattern ranging from 50 - 150
mm (2''- 6'') at a 150 mm (6'') spray distance, by adjusting the secondary air pressure. The
spray pattern width can be increased to 300 mm (12'') by increasing the spray distance to
300 mm (12''). This may, however, adversely affect the coating properties, i.e., hardness,
density/porosity and deposit efficiency
3. Standard spray distance 4''- 6'' (101.6 mm - 152.4 mm).
4. Unit is packaged with standard hardware to spray 14 ga. hard wires. For other wires see Arc
Wire Setup Hardware Table, this section.
5. For further material coating characteristic information, refer to appropriate tech bulletin.
6. Wire required and coverage figures are based on spraying large, flat surfaces with little
overspray loss.
CAUTION
Be Sure Proper Contact Tips, Contact Tubes, Wire
Guides, And Drive Rolls Are Installed In Gun And
That Proper Lower Drive Roll Is Installed In
Controller. Refer To Arc Wire Setup Hardware Table,
This Section.
NOTE
For further material coating characteristic information,
refer to applicable technical bulletin.

Spraying Table - SmartArc Gun

HIGH VELOCITY AIR CAP (Metric System)
Sulzer
Metco
Wire
(NOTES 3, 4)

Air Pressure
bar

Operating
Parameters

Hourly
Consumption

Coverage
(NOTE 6)
m2/h/0.1mm

Primary
(NOTES 2)

Clamping

Amps

Volts
(NOTE 1)

kg Wire

kW Input
(Approx)

kg Wire
Required
per m2/
0.1mm
deposited

Metcoloy #2

2.4

1.7-2.4

200

28-32

8.2

6,000

0.73

12.10

Metcoloy #5

2.4

1.7-2.4

200

26-28

9.1

5,500

0.87

10.48

SM 8400

2.4

1.7-2.4

200

26-28

9.1

5,500

1.08

8.48

SM 8276

2.8

1.7-2.4

200

30-34

9.1

6,500

0.99

9.08

Sprabronze AA

2.4
2.4

1.7-2.4
1.7-2.4

200
350

28-32
28-32

6.8
13.6

6,000
10,500

0.99
0.99

6.81
13.62

Aluminum AW, 14
ga.

2.4

1.0-1.4

200

26-28

4.5

5,500

0.42

10.86

Zinc AW,
14 ga.

2.4

1.4-2.1

200

21-23

17.7

4,500

1.09

16.23

Copper

2.4

1.7-2.4

200

26-30

11.3

5,500

0.93

12.22

Spraying Table - SmartArc Gun

HIGH VELOCITY AIR CAP (English System)
Sulzer Metco
Wire
(NOTES 4, 5)

Air Pressure
psi

Operating
Parameters

Hourly Consumption

lb Wire
Required
per ft2/0.001
in. deposited

Coverage
(NOTE 7)
ft2/h/0.001
in.

Primary
(NOTES 2, 3)

Clamping

Amps

Volts
(NOTE 1)

lb Wire

kW Input
(Approx)

Metcoloy #2

35

25-35

200

28-32

18

6,000

0.04

510.00

Metcoloy #5

35

25-35

200

26-28

20

5,500

0.05

443.52

SM 8400

35

25-35

200

26-28

20

5,500

0.06

358.97

SM 8276

40

25-35

200

30-34

20

6,500

0.05

384.38

Sprabronze AA

35
35

25-35
25-35

200
350

28-32
28-32

15
30

6,000
10,500

0.05
0.05

288.29
576.57

Aluminum
AW,14 ga.

35

15-20

200

26-28

10

5,500

0.02

459.59

Zinc AW,
14 ga.

35

20-30

200

21-23

39

4,500

0.06

687.08

Copper

35

25-35

200

26-30

25

5,500

0.05

517.44

10

HIGH VELOCITY AIR CAP NOTE

1. The voltage range shown under Operating Parameters should be adjusted to provide a
smooth and stable arc. If the voltage is set too high, the spray pattern may be poor causing
large particles to be deposited on the spray surface. If the voltage is set too low, particularly
with the hard wires, the arc may be erratic and cause a popping sound. Under this condition,
raise the arc voltage until the popping stops; then increase one to two more volts (voltage is
recorded at the gun).
2. High Velocity Air Cap reduces the spray pattern width compared to the Fine Air Cap.
3. Air consumption for high velocity air cap at 35 psi (2.4 bar) is 30 CFM (850 liter/min).
4. Standard Spray Distance is 4'' - 6'' (101.6 mm - 152.4 mm).
5. Unit is packages with standard hardware to spray 14 ga hard wires. For all other wires, see
Arc Wire Setup Hardware table.
6. Do not spray 11 ga. arc wire with the high velocity air cap.
7. Wire required and coverage figures are based on spraying large, flat surfaces with little
overspray loss.

CAUTION
Be Sure Proper Contact Tips, Contact Tubes, Wire
Guides, And Drive Rolls Are Installed In Gun And
That Proper Lower Drive Roll Is Installed In
Controller. Refer To Arc Wire Setup Hardware Table,
This Section.
NOTE
For further material coating characteristic information,
refer to applicable technical bulletin.

11

12