Installation guide: Stable ultrasonic atomizing nozzle performance depends on the air and water available at every nozzle, the mounting method, the surrounding airflow and a controlled commissioning sequence. Use the verified SK508, SV882 and SV980 utility data below to size the system before installing the header.
Before installation
Confirm the selected model, nozzle quantity, available air pressure and continuous air flow, water pressure, mounting style and process conditions. The compressor and piping must support every nozzle that will operate at the same time. Check capacity under normal plant load, not only when other pneumatic equipment is idle.
Review the engineering selection guide if the model has not yet been fixed.
Size the air and water supply from verified per-nozzle data
| Model | Air pressure | Air flow per nozzle | Water pressure | Water flow per nozzle | Listed pattern |
|---|---|---|---|---|---|
| SK508 | 5.0 bar | 112 L/min | 1.0 bar | 0.359 L/min | 80°, ≈2 m no wind |
| SV882 | 5.0 bar | 240 L/min | 1.0 bar | 0.746 L/min | 60°, ≈3.5 m no wind |
| SV980 | 3.0 bar | 307 L/min | 0.5 bar | 0.688 L/min | 30°, ≈4 m no wind |
Spray distances are approximate no-wind values. Confirm pressure and flow at the operating nozzle, after regulators, valves, filters, fittings and line losses.
Total flow calculation
For a single-model header:
- Total air flow = air flow per nozzle × maximum simultaneous nozzle count.
- Total water flow = water flow per nozzle × maximum simultaneous nozzle count.
For example, four SK508 nozzles require a listed total of 448 L/min air and 1.436 L/min water when all four operate. This is the nozzle demand only; compressor and piping selection must also account for pressure loss, control response and other plant users.
Utility layout
- Use stable, clean compressed air and an appropriate filter/regulator arrangement for the system.
- Use suitable water filtration for the liquid quality and process.
- Provide pressure measurement close enough to the header to reveal pressure loss under full flow.
- Support pipes and hoses so their weight and vibration are not transferred to the nozzle body.
- Provide isolation so a section can be inspected without shutting down unrelated equipment.
Mounting options and connections
The documented water inlet is G1/8 and the air inlet is G1/4. Verify the ports before fabricating the mating assembly.
Common adapter
The common type can be welded or fixed by another suitable method at the working point. Align it before final fixing, protect the nozzle from fabrication debris, and keep enough clearance for connection, inspection and removal.
Thin-wall adapter
The thin-wall type is installed through an opening and secured with its retaining cap. Make sure the wall can support the assembly without distortion. Tighten the retaining parts evenly and confirm that the nozzle remains correctly oriented.
The parameter drawing identifies an approximately 75 ± 1 mm overall length for both adapter styles. Confirm the final drawing for fabrication, especially when panel thickness, clearances or custom mounting details are critical.
Header layout, spacing and orientation
There is no universal nozzle spacing because coverage changes with the selected model, mounting height, airflow and acceptable overlap. Start from the listed angle and no-wind distance, then test the pattern in the actual process.
- Straight header: useful for linear zones such as a conveyor, opening or work area.
- Ring or perimeter layout: useful when mist must approach a source from several directions.
- Orientation: position the spray so process airflow supports coverage rather than immediately carrying the mist away from the target.
- Access: leave space to observe the plume and service the nozzle without dismantling the entire header.
Avoid pointing the spray directly at nearby walls or equipment unless surface wetting is intended. Where cross-drafts exist, perform a live coverage test before fixing every bracket permanently.
Commissioning sequence
- Inspect the air and water lines and remove fabrication debris before connecting the nozzles.
- Confirm that air and water are connected to their documented ports.
- Check that every nozzle is secure and correctly oriented.
- Start with the system controls in a safe condition and bring the utilities on according to the plant procedure.
- Set the specified air and water pressure while the nozzle is flowing.
- Operate all intended nozzles simultaneously and check pressure at the far end of the header.
- Observe spray angle, reach, uniformity, drift and unintended wetting.
- Record the working pressures, active nozzle count and any regulator settings as the commissioning baseline.
Do not judge the system from a static pressure reading. A header can show the correct pressure with the nozzles closed and still fall below the required condition under full flow.
Initial troubleshooting
For a complete symptom-to-cause workflow, see the ultrasonic nozzle troubleshooting guide.
| Symptom | First checks |
|---|---|
| Weak or short spray | Check full-flow air pressure, compressor capacity, line restrictions and whether too many nozzles opened together. |
| Uneven mist between nozzles | Compare pressure along the header, inspect branches and confirm that every nozzle uses the intended model and orientation. |
| Intermittent output | Check supply stability, valves, filters and possible contamination in the air or liquid path. |
| Excess surface wetting | Review model angle, mounting distance, water setting, nozzle overlap, ventilation and ambient humidity. |
| Drift away from target | Inspect cross-drafts and reposition the nozzle or shield the spray zone where appropriate. |
For persistent issues, record the model, active nozzle count, pressure under flow, air and water supply conditions, photos or video of the spray, and the process airflow. This evidence is more useful than a symptom description alone.