A device for calibrating a spray gun and an associated method are provided. The spray gun has a nozzle that is opened and closed by moving an internal needle out of and into sealing engagement therewith. A virtual position of the needle is tracked and recorded. The control system is recalibrated when the virtual position and the actual position of the needle do not correspond. The device includes a sensor structured to detect characteristics of the current used to power the solenoid, and to identify an anomaly in solenoid current characteristics associated with an actuator member seating against the solenoid. The solenoid is placed in a calibration configuration and the identifiable anomaly is detected. When the identifiable anomaly is detected, the spray gun is returned to an initial configuration and the virtual needle position is reset. The virtual needle position and the actual needle position are then calibrated.