2850 owner's manuals-manual.pdfpower: 120 vac, 7 amp 200-240 vac, single phase, 4 amp air: 5-6...

AutoJet Technologies – PO Box 7901 – Wheaton, IL 60189-7901 – 1-866-321-2250

2850 OWNER’S MANUAL 03/01/2019 rev 1

- 2 – AutoJet Technologies

PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Table of Contents

1) General Safety information ......................................................................................................... 3

Spray Safety Information ................................................................................................................ 4

2) Utility requirements and specifications ....................................................................................... 5

3) Installation ................................................................................................................................... 6

4) System Familiarization ................................................................................................................ 8

5) System Operation ...................................................................................................................... 12

6) 2850 Controller Menu Structure ................................................................................................ 17

Operating screen ........................................................................................................................... 17

Main Menu .................................................................................................................................... 18

System Configuration ................................................................................................................... 19

Sensors and actuators .................................................................................................................... 27

Alarm settings ............................................................................................................................... 30

Monitor I/O ................................................................................................................................... 33

Zone Control ................................................................................................................................. 37

Help ............................................................................................................................................... 38

7) Clogging and System Performance ........................................................................................... 39

Prevention ..................................................................................................................................... 39

Simplifying cleanup ...................................................................................................................... 39

8) Troubleshooting and Faults ....................................................................................................... 40

Faults ............................................................................................................................................. 41

9) Recommended Maintenance ..................................................................................................... 42

Spray Gun and Header Maintenance ............................................................................................ 43

10) Appendices ............................................................................................................................. 44

Appendix A, Spray gun components ............................................................................................ 44

Appendix B, Liquid Regulator Components (not applicable) ...................................................... 45

Appendix C, Extrusion cross section detail .................................................................................. 46

Appendix D, Recommended Spare Parts ...................................................................................... 47

11) Warranty Information ............................................................................................................ 48


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

1) General Safety information

a) Warning of shock hazard

To reduce the risk of electric shock, only authorized qualified service personnel should attempt to service this unit. For service contact Spraying Systems at 1-866-321-2250.

b) Read and follow instructions

All safety related and operating instructions should be read before the system is operated. Follow all operating instructions.

c) Power sources

The control system should be operated only from the type of power source indicated on the product’s builders tag. If you are not sure of the power source, consult an electrician or qualified service personnel.

d) Water and moisture

The control panels are rated NEMA 4x and are protected against dust and incidental splashing water.

e) Servicing

Only trained personnel should attempt repairs on this equipment. Opening the cover of the electrical panel may expose you to dangerous voltage or other hazards. For service contact Spraying Systems at 1-866-321-2250.

f) Replacement parts

The spray system has been designed with components that work together to provide the best system performance. When the system requires replacement parts, only Spraying Systems recommended components should be use to maintain proper system operation and maintain electrical and pneumatic safety.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Spray Safety Information

WARNING: It is important to recognize proper safety precautions when using a pressurized spray system. Fluids under pressure can penetrate skin and cause severe injury.

WARNING: When dealing with pressure applications, the system pressure should never exceed

the lowest rated component. Always know your system and all component capabilities, maximum pressures and flow rates.

WARNING: Before performing any maintenance, make sure all electrical, air and liquid supply

lines to the system are shut off and /or disconnected. WARNING: The use of any chemicals requires careful control of all worker hygiene.

WARNING: AutoJet Technologies does not manufacture or supply any of the chemical components used in this equipment and is not responsible for their effects. The buyer and user of this equipment should determine compatibility of the materials used and any of the potential hazards involved.

WARNING: AutoJet Technologies strongly recommends the use of appropriate safety equipment when working with potentially hazardous chemicals. This equipment includes but is not limited to:

Protective hat Safety glasses or face shield Chemical-resistant gloves and apron Long sleeve shirt and long pants

Always remember to carefully read the chemical manufacturer’s label and follow all directions.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

2) Utility requirements and specifications

System utility requirements: Power: 120 VAC, 7 Amp 200-240 VAC, single phase, 4 Amp Air: 5-6 bar (75-90 PSI), 142 NLPM (5 SCFM) OR 15 SCFM with

vortex cooler installed, 3/8” NPT connection. Air atomizing possibly will be used in the future.

(3/8” OD tube connection) Required air quality:

o Clean, dry air according to DIN ISO 8573-1 o Solids - Class 5 o Water content – at least class 4 (*) - Cooled down to 59° F

below room temperature (location of system) o Oil content – at least class 5

Specifications

Flow rate (typical) - ≈ 0.09 - 0.11 GPM/gun @ 40 PSI for 6501 tips Maximum allowable - 100 PSI air in system pressure Environmental - Operating temperature range: 32° to 113° F (0° to 45° C) Humidity Range: 5 to 95% (non-condensing) Enclosures: Stainless steel, NEMA 12


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

3) Installation

The system consists of a pump skid with an electrical control panel , one strainer/pulsation dampener/pressure sensor assembly, flow meter assembly and eight nozzles with 5/16” tee connectors.

Pump Skid and Electrical panel

Vortex Cooler


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

System Integrity Flow Meters

Spray Nozzles

Pulsation dampener assembly


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

4) System Familiarization

Spray Nozzles The PulsaJet spray nozzles are high speed electric nozzles designed for controlling flow by pulse width modulation. Rather than adjusting flow by the traditional means of varying the pressure, the flow is controlled by switching the guns on and off rapidly during spraying. The ratio of the "on" time to the "off" time results in some percentage of the maximum possible (continuous) flow through the nozzle; this is called the "duty cycle" of the spray gun. The system may be equipped with diverter valves to allow the header to be flushed and filled remotely (not included). This self-cleaning feature is controlled electronically from the controller or by external signal. The operating frequency, or number of times the gun is switched on and off per second, is determined by the line speed and desired appearance of the end product. It is set to 100FPM initially for the blender application. Too low of a frequency can result in a striped appearance in the sprayed surface; too high of a frequency results in excess wear on the guns and limited adjustability of the duty cycle. Electrical Panel The main electrical panel contains the controller for the system and all supporting electronics. The front panel is equipped with a 10 inch touch screen, POWER ON, POWER OFF, Spray triggers, reset and alarm acknowledge buttons. The reset buttons may be used for operating the system manually, without an external product sensor but are otherwise not used under normal operating conditions.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Electrical panel interior The electrical panel houses the spray controller, electronically controlled current to pressure converters (I/P), manual I/P override, the power supplies and zoning modules.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

I/P Proportional Regulator a) Valve Function - 3-way closed proportional-pressure regulator

Flow meters (optional) The flow meters can be located in a variety of orientations, but ideally should be installed so that the flow is traveling upward through the instrument. If mounted in a horizontal orientation, the unit should have an upward pitch to allow air to pass through without being trapped. The flow direction is configurable through the flow meter interface; see the manufacturer's instructions for correct configuration and operation.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

5) System Operation

Starting the system:

1. Ensure the inlet to the pump on the pump skid is connected to a fluid source. 2. Make sure all valves on pump are oriented closed or open depending on which outlet is

being used. 3. Turn on the air supply if the system switches over to air atomizing. Check for leaks before

proceeding. 4. Turn the system on and wait until the controller boots. 5. The 2 channels are controlled independently. Press the Ch1 Run/Standby Button to

activate/deactivate channel 1. When in Standby mode, all triggers, inputs associated with that channel will be ignored.

Press the AutoJet logo for the drop down navigation menu.

See section 6 for actual screens


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Flushing the system:

1. Ensure that a catch pan is in place under each header if necessary, and that the waste line from the outlet valve assembly at the far end of the headers is routed to a suitable drain or collection vessel.

2. Press the AutoJet Logo button at the upper right corner, followed by the Monitor IO to go to the monitor IO screen. Navigate to the "Flush/Fill" button at the bottom.

3. Enter the amount of time needed to flush the system. Press the Flush button to begin flushing. The system will first flush the header with water with the nozzles off. When the flush sequence is complete, the system will turn on the nozzles to flush the nozzles with water. Note that the manifold and liquid supply tubing from the inlet valve assembly to the headers is filled with water. A fill sequence must be run prior to using the system for production

Filling the system (optional but not purchased):

1. Ensure that a catch pan is in place under each header if necessary, and that the waste line from the outlet valve assembly at the far end of the headers is routed to a suitable drain or collection vessel.

2. Press the AutoJet Logo button at the upper right corner, followed by the Monitor IO to go to the monitor IO screen. Navigate to the "Flush/Fill" button at the bottom.

3. Enter the amount of time needed to fill the system. Press the Fill button to begin filling the header. When the fill sequence is complete, the system will turn on the spray nozzles to fill


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

the nozzles for the specified time. When sequence is complete, the system is ready to spray

In both the fill and flush sequences, the outlet valve assembly opens, allowing a high volume of liquid to pass through the headers in a short time. The guns will also spray once the header is filled with water or chemicals as required.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

5) System Operation, continued

Normal running (spraying)

1. Press the Ch1 Run/Standby to put the system in run mode. Below shows 2 Channels.

2. Press the Autojet button for the drop down menu. From there press the Ch1 Regulation and Timing

Enter the desired regulation mode, and spray timings.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

3. At the bottom press Ch1 config button

Note: Gun timings are visible only if SSCO is logged in. The number of channels will be automatically selected depending if a 2nd 2008 has been detected. Select the correct Spray Nozzle. Enter the desired reference parameters.

4. Sensors and Actuators:


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

6) 2850 Controller Menu Structure

Operating screen

Upon startup, the operating screen is displayed. The operating screen is the screen that is normally used during regular operation. It displays the state of the machine and the current operating parameters.

Liquid Pressure (read only): The liquid pressure is displayed from a pressure transmitter

located on the inlet valve assembly. The controller uses feedback from this transmitter to hold the pressure at a constant value based on the programmed setpoint.

Atomizing Air Pressure (read only): Current pressure of the atomizing air. Line Speed (read only): The line speed, whether real or simulated is displayed here. Application Rate (read only): The current application rate output by the 2850. Flow Rate (read only): The flow rate is displayed, using either actual flow meter data

or a simulated value. It is normal for some fluctuation in the displayed value.

Frequency (read only): The spray gun operating frequency is displayed here. It is a

function of the line speed and stripe width programmed on the setpoints screen.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

2008 Duty cycle (read only): The current duty cycle (ratio of the ON time to the OFF time)

output of the spray guns is displayed here. Theoretical Max Flow Rate (read only): The maximum flow rate based on liquid pressure

reference flow and reference pressure of the tip. These screen lines are duplicated for Channel 2.

Main Menu

Push the Autojet Logo in the upper right to present the dropdown navigation menu. The Main Menu screen is used to navigate to all other screens on the controller interface. Certain lines may not appear unless the proper credentials are entered.

Operating Screen (screen) - Jumps to the Operating Screen. System Configuration (screen) - Jumps to the System configuration screen.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Sensors and Actuators (screen): Jumps to the Sensors and Actuators screen. Alarms (screen): Jumps to the Alarms screen. Monitor I/O (screen): Jumps to the Monitor I/O screen. Zone Control (screen): Jumps to the Zone Control configuration screen. Help (screen): Jumps to the Help screen. HMI OS (screen): Jumps to HMI OS. Log In (screen) - Log in user credentials.

System Configuration

The System Configuration screens allows the operator to control spray patterns and behavior. In the configuration page, the operator can input parameters that will control the nozzle.

Number of Channels (read only) - Displays the number of channels in the system. The 2850 detects the number of 2008 modules installed in the system only when the screen powers up. If only 1 2008 channel is detected, options to configure channel 2 will be hidden


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Spray Nozzle Select (editable) - Select the nozzle the 2850 will be controlling. There are Default settings will be loaded depending on nozzle selected. There is an OTHER selection for custom settings.

Nozzle Type (read only) - Identifies whether the nozzle selected is a PWM

nozzle or air actuated. Max cycle (editable) - Enter the number of cycles/minute allowed by the

spray gun. This is used to calculate the GUN signal frequency.

Min Cycle (editable) - Enter the minimum number of cycles/minute the

system should try to maintain. This is used to calculate the GUN signal frequency.

Anticipator Time (editable) - Enter the time the atomizing air is on before

the spraying is started. Follower Time (editable) - Enter the time the atomizing air is on after the

spraying has stopped. Reference Pressure (editable) - Enter the pressure at which the flow is tested, or

catalog data if unknown. Reference Flow (editable) - Enter the flow rate of a single nozzle at the reference

pressure. If unknown, use the catalog data. Startup Mode (editable) - Determines whether the system boots up in standby

or in run mode. Zone Control (editable) - Toggle to enable/disable zone control. Spray Width (editable) - Enter the spray width of the entire header.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Regulation and Timing

Variable Spray Settings (editable) - This line allows selection of the trigger type: Follower follows the input signal. Time allows a time delay between the trigger signal

and the spray. Distance allows a distance delay between the trigger

and the spray. Number of Triggers (editable) - If trigger is selected, the system will spray as long as

the start trigger is held high. If trigger/reset is selected, the system will spray

continuously after the start trigger is held high momentarily. The spray is stopped by holding the reset trigger momentarily.

Repetition (editable) - This option allows the operator to add additional

spray and delay distances to spray a repeating pattern onto a part on a conveyor within a single trigger cycle. This is used to spray objects like trays with an array of depressions, where it is desirable to spray into the depressions but not onto the rest of the tray.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Regulation (editable) - Constant Pressure, Air Act: Uses I/P to regulate liquid pressure. Used with air actuated nozzles.

Constant Flow, Air Act: Uses I/P to regulate flow.

Used with air actuated nozzles. Constant Flow, PWM: Based on the liquid pressure,

reference flow and pressure, the controller will calculate the correct duty cycle to maintain the flow rate setpoint. Used with PWM nozzles only.

Volume/Unit Area, PWM: This sets the system to

apply a constant application rate of liquid per unit of surface area of substrate on a moving conveyor. The flow rate of liquid will vary as the line speed ramps up or down, but the add-on rate to the substrate will remain fixed. Used with PWM nozzles only.

Freq & Duty Cycle, PWM: This allows manual entry

of frequency and duty cycle. Gun output will not be determined by normal application logic. Used with PWM nozzles only.

Fixed/Variable spray time/distance Fixed spray time/distance: A fixed time or distance is

entered for the spray. both the spray and the delay. Variable spray time/distance: The system will track

how long the trigger has been held then spray for that amount of time or distance. A delay time/distance can be entered to delay the spray.

Delay time/distance (editable) – The measured distance in inches between the

photoeye or other trigger sensor and the spray zone. This can be adjusted to start the sprays before or after the leading edge of the part on the conveyor.

Delay Time/distance (editable) – The time/distance between the photoeye or other

trigger sensor and the spray zone. The system will wait the specified time or distance before spraying for the entered spray time distance.

Flow rate SP (editable) – Enter the desired flow rate. The system will vary the

duty cycle to achieve this setpoint. Application rate SP (editable) – Enter the desired application rate. The system will

vary the duty cycle to maintain the amount of fluid distributed per surface area on a moving conveyor. The rate of liquid will vary as the line speed varies but the add-on rate to the substrate will remain fixed.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Liquid Pressure SP (editable) – Enter the desired liquid pressure. The system will vary either the pump speed or I/P to maintain the desired liquid pressure.

Remote Setpoint (read only): Displays the setpoint currently set by the user using

the analog inputs. Remote setpoint will vary between flow rate and app rate depending on what regulation mode is selected.

PID settings screen


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Liquid Pressure PID:

The graph is a trend of the setpoint and process value versus time. Liq Pressure Setpoint (editable): Enter desired liquid pressure (PSI). Liq Pressure Process Value (read only): Display of the current liquid pressure. Liq Pressure P-Gain/I-Time (editable): Enter the desired P and I value for PID control. Reset (executable): Resets the graph.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Atomizing Air PID

The graph is a trend of the setpoint and process value versus time. Atomizing air setpoint (editable): Enter desired liquid pressure (PSI). Atomizing air process Value (read only): Display of the current liquid pressure. Atomizing air press. P-Gain/I-Time (editable): Enter the desired P and I value for PID control. Reset (executable): Resets the graph.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Duty Cycle PID

Application rate SP (editable): Enter the desired application rate. The system will vary the duty cycle to maintain the amount of fluid distributed per surface area on a moving conveyor. The rate of liquid will vary as the line speed varies but the add-on rate to the substrate will remain fixed.

Application rate process value (read only): Display of the current application rate based

on current flow and line speed Duty cycle correction factor (read and edit): Display of the correction factor calculated by

the PLC. The correction factor is added to the duty cycle to account for application rate and line speed. The correction factor becomes editable if the PID loop is disabled.

Kp/Ki (read only): P and I values for PID control of the duty cycle. Duty Cyle (read only): Current duty cycle as read from the 2008 modules Flow rate (read only): Current flow rate. Line speed (read and editable): Current line speed. A line speed can be

manually entered if selected in the sensors page. PID Delay (editable): The delay before the PID loop will take in effect.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Reset (executable): Resets the graph.

Sensors and actuators

In the Sensors and actuators screen, the analog inputs are configured here. If a sensor is not installed, then values can be entered in manually. Variables will appear and disappear depending on the selection.

Line speed signal input (editable): Select from where the line speed will be read: High speed counter (encoder), or analog input (mA) .

K-factor (editable): A calibration factor that converts the number of pulses

counted into inches traveled.

Span (editable): Sets the span (20mA) of the analog input. 4mA will always correspond to a 0 value.

Filter (editable): Enter the filter constant for the analog input to

dampen out noise.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Analog output configuration

Analog output configuration page sets the span of the analog outputs. 4mA will always correspond to 0 value. Frequency and duty cycle span is only settable when in Freq & duty cycle, PWM is selected in the regulation and timing page.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

System integrity

System integrity is a feedback system that checks the operation of certain nozzles and tips. Number of nozzles (editable): Enter the number of nozzles on the header. Flow meters (editable): Enter the number of flow meters attached to the

header. Tolerance % (editable): Based on the nozzle information, the system will

calculate the theoretical flow for each flow meter. Using the theoretical flow and tolerance %, an acceptable window is established.

Tolerance Time (s) (editable): This is the amount of time the flow meter must read

outside the acceptable window before the system alarms.

SI Span (GPM) (editable): Sets the analog input span on the PLC for system

integrity. Flow meter readings (read-only): Displays the current readings of the system integrity

flow meters.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Flow meter association (editable): Enter the flow meter to which the nozzle is plumbed. Nozzle Number (read-only): Displays the nozzle number on the header. Tip reference flow (GPM) (editable): Enter the reference flow for the tip installed on the

nozzle.

Alarm settings

Alarm settings page sets the condition that will cause an alarm by the PLC. The sensor can either be enabled or disabled.

Liquid pressure alarm Min/max pressure (editable): Enter the minimum and maximum operating liquid

pressure. Tolerance time (editable): Enter the amount of time the liquid pressure must be

outside the operating range before alarming. Flow alarm


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Low/high percentage (editable): Sets the acceptable operating flow of the system. The acceptable range is determined by multiplying the setpoint by either the low percentage or high percentage.

Tolerance time (editable): Enter the amount of time the liquid flow must be

outside the operating range before alarming. PWM Alarm Tolerance time (editable): Enter the amount of time the duty cycle must be

outside the operating range before alarming. The optimal operating range is hard coded to be 92% - 8%. Outside of this range and the PWM alarm will become active.

Application rate alarm Low/high percentage (editable): Sets the acceptable operating application rate of the

system. The acceptable range is determined by multiplying the setpoint by either the low percentage or high percentage.

Tolerance time (editable): Enter the amount of time the application rate must be

outside the operating range before alarming.

Atomizing air pressure alarm Min/max pressure (editable): Enter the minimum and maximum operating

atomizing air pressure. Tolerance time (editable): Enter the amount of time the atomizing air pressure

must be outside the operating range before alarming.

Liquid level alarm Tolerance time (editable): Enter the amount of time the liquid level must be

tripped before alarming.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Active Alarms

Active alarms screen shows the current alarms that are active. Removing the alarm condition will remove the alarm from this screen but will still be recorded in the alarm history. The alarms will be

recorded in the alarm history until alarm reset is pressed.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Monitor I/O

Monitor I/O page monitors the IO of the PLC and to some extent the 2008 modules. The triggers can be toggled in the monitor IO page if the system is in standby for that channel. The PLC output duty cycle can be set if that channel is in standby. The actual duty cycle is the duty cycle output by the 2008. This is read directly from the 2008.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Analog IO Monitor

Slots 1 and 2 are analog input cards. The displayed value is the number of counts received. Divide by 1000 and that will correspond to the mA received. Slots 3 and 4 are analog output cards. The displayed value is the number of counts being sent. Divide by 1000 and that will correspond to the mA sent.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Plugin Relay Output Monitor

Plugin relay output page displays the status of the relays of the plugin modules (located on the top of the PLC). These are primarily used for zone control. They can be toggled on/off even if the channel is running.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Flush/Fill

The Flush/Fill screen allows the user to configure and control the flush/fill cycles.

Recipe select (editable): The user can select which nozzles to fire during the flush/fill cycle by selecting the appropriate recipe. The recipes are programmed and set in the zone control screen.

Flush hdr time (editable): Enter the amount of time to flush the header. During this time the flush valve and the drain valve will open. The nozzles will not fire at this time

Flush nozzle time (editable): Enter the amount of time the nozzles will fire to flush. This takes place automatically after the header is flushed. The nozzles will fire at this time

Fill time (editable): Enter the amount of time to fill the header with chemicals. During this time the flush valve will close and the drain valve will open.

Fill nozzle time (editable): Enter the amount of time the nozzles will fire to fill the header with chemicals. This takes place automatically after the header is filled. The nozzles will fire at this time

Time remaining (read only): This line shows the user the amount of time left in the cycle. This number will tick down to zero allowing the user to clearly see that the cycle is indeed occurring or done.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Zone Control

Zone control setup screen can only be accessed if it is enabled in the configuration screen. This screen allows the operator to change the parameters specific to the zones on the headers. The user uses the zone control screen to determine which guns will be active and which will be deactivated during process. The configuration will be saved in recipes. In the operation screen, the user can select the recipe to run and the proper zone configuration will be used.

Zone spray width (editable) - Enter the spray width of the entire spray.

Zone reference flow (editable) - Enter the flow rate of all active nozzles. Typically the reference flow of all the tips are simply added together.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Help

Information such as vendor revision and serial number of the 2008 can be found in the help screen.

Screen Map


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

The screen map allows the user to jump to any screen. The change password button allows the user to change its password. The user must be logged in and can only change passwords of themselves or any user with lesser credentials.

7) Clogging and System Performance

Generally, the most immediate problem faced by operators is nozzle clogging. If cleaning is required, a plastic brush should be used to clean the exterior portions of the spray guns and nozzles. Metal brushes, sharp objects, etc. can damage the nozzles and should not be used.

Prevention

1. Debris inside the fluid tips – this is common on new installations and it will cause skewed spray patterns. All of the fluid tips should be removed and cleaned out, taking special care that all of the holes are clear. This may need to be done more often after the system is first commissioned, since all of the manufacturing debris – Teflon tape, metal shavings, paste pipe sealant, etc. will get caught in the small passages. Once the internal passages of the delivery system and header are free from debris, the need for this level of cleaning should become infrequent.

2. The fluid orifices are very small and clog easily. The spray patterns should be checked

frequently during operation until a history of operation can be determined.

3. Perform a flush cycle if the system is to sit idle. All testing performed by Spraying Systems Co. indicates that a clean nozzle tends to stay clean longer, but once buildup starts, it gets out of control very quickly.

4. If spray guns/nozzles are clogging quickly, even after they are cleaned, the process liquid may need to be changed out in the system.

Simplifying cleanup

1. Except for the electrical junction block, the entire header may be removed and pressure washed with 1000 PSI water. If the complete header is pressure washed, do not spray water onto the junction block. DO NOT ATTEMPT TO STEAM CLEAN THE HEADER OR USE CAUSTIC SOLUTIONS AS THIS WILL DAMAGE THE ANODIZED FINISH ON THE HEADER COMPONENTS.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

8) Troubleshooting and Faults

Troubleshooting Equipment required: Multimeter (voltage/current/ohms) Beaker (size as needed) Scale or balance (milligram resolution) * The main 115VAC power source should be checked and verified as the first step before any further troubleshooting is begun. * Check and verify unregulated valve power supply voltage 24vdc (21vdc-29vdc). * Check system and power supply fuses if there should be no voltage(s) measured. * Check the HMI for fault messages. * Check and verify system air pressure. * Check and verify liquid in the tanks. Before you start looking to see if a device is not working please insure that all the electrical, pneumatic and hydraulic connections are secure and in their proper places. If you have any manual valves in place make sure they are in the proper orientation to provide the necessary media. Make sure the controller is in run mode. If the system is in standby mode it will ignore all attempts to trigger the system. It must be in run mode to accept any trigger. System: Trigger is applied, nothing is coming out of the guns?

• look at the operating screen and see what the duty cycle is during the trigger sequence. If it is zero than make sure you have a line speed, if simulated make sure it is above zero and preferably around 100 fpm just to test. Look at the duty cycle and if it is zero than you will need to adjust your application rate to a value that produces a decent duty cycle, something above 10%.

• If you still have no flow and a good duty cycle then try and get near the guns and determine if they are cycling. If they are then you will need to start looking at the fluid path. Make sure the guns have pressure to the manifold. You should see a pressure reading on the operating screen that is report back from the transducer. If this is the case then re-check the electrical connections from the panel to the terminal block on the header.

• If you do not have pressure out to the header but do have pressure to the inlet side of the liquid regulator on the bottom of the panel then check the following:

1. Verify that the liquid pressure I/P span is set correctly. 2. Check to make sure you have a good liquid pressure set-point. For these trials it

should be in the range of 30-40 psi. Check to make sure you have air pressure supplied to the system and it is turned on.

3. Check to see if the I/P is putting out pilot pressure to the regulator. Remove the air pilot line and double check to see if air is present from the I/P. The system needs to be triggered in order to verify this.

Electrical:


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Pressure transducer outputing 0 value

• If "NOT INSTALLED" is displayed on sensors screen then the transducer is wired incorrectly. Verify the wiring first at the transducer and then at the panel.

• If a fixed (you see a fixed value) is displayed on the HMU , usually 100 psi then chances are the transducer has failed. Rplace the pressure transducer.

Faults

Problem Possible cause

Pressures go to maximum Cables switched on pressure transmitters or open circuit in pressure transmitter cable

Guns spraying intermittently

Liquid pressure set too low Air inside manifold Supply vessel empty

No liquid pressure Atomizing air setpoint set to zero Pressure pot valve(s) in the "depressurize" position

Liquid pressure setpoint set to zero

Liquid pressure analog output wired improperly.

Guns spitting Debris on or inside fluid cap


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

9) Recommended Maintenance As needed: * Perform system flush. * Clean exterior of nozzles with plastic brush and water or solvent. Daily: * Check all spray guns for leaks or mechanical malfunctions. Repair or replace as required. * Clean exterior of header. Every two - three weeks: * Perform system flush. Monthly: * Check all liquid connections for leaks and repair or replace as required. * Check all tubes and/or hoses for leaks and repair or replace as required. * Check liquid components for leaks and repair or replace as required. * Clean liquid filters.. Every 6 Months: * Overhaul spray guns as necessary.

NOTE: Any long term shut-down requires that all liquid lines, liquid components, pumps and spray guns be flushed and cleaned thoroughly.


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Spray Gun and Header Maintenance To replace a clogged nozzle In the event of a clogged nozzle, the nozzle setups can be removed and replaced without removing the spray gun or depressurizing the header.

1. Remove the retainer and fluid tip and clean or replace as needed.

2. Depending on the type of spray gun installed, the fluid tip may be dovetailed to fit into the gun body in only one orientation, or it may be adjustable. If dovetailed, replacement involves only sliding the fluid tip in sideways and tightening the retainer. If adjustable, the orientation must be set as the retainer is tightened.

3. All edge spray tips (UB) will use a Teflon gasket (CP4743-TEF). If dovetailed spray gun is installed,

an insert (CP58695-SS) must be used along with a retainer cap (CP1325-SS).


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

10) Appendices

Appendix A, Spray gun components


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Appendix B, Liquid Regulator Components (not applicable)


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Appendix C, Extrusion cross section detail


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

Appendix D, Recommended Spare Parts

Description SSCo P/N Quantity

Pressure Transmitter, 4-20mA, 0-100 PSI PR00W8392416 1

PulsaJet Electric Spray Nozzle AA10000AUH-03 2

PulsaJet Spray Nozzle - Electrical rebuild kit AB10000-ELEC-VI-KIT 1

PulsaJet Spray Nozzle - Plunger, spring rebuild kit AB10000AUH-03-VI-KIT 1

Strainer, Nylon (includes screen) AA122-1/2-NYC-100 1

Strainer(PP) Screen, 100 mesh, 304SS CP45102-5-SSPP 1

Screen, Stainless Strainer, 100 mesh, 304SS CP5594-8-304SS 1

Sola Power Supply, 24 VDC, 5 Amp PY00SDN524100C 1

Sola Power Supply, 24 VDC, 10 Amp PY00SDN1024100C 1

UniJet Spray 03 Tip Setup, 65 degree TPU6501-SS 2

Gasket, Teflon CP4743-TEF 2

Retainer nuts CP1325-SS 2

T-Nut, M4, Stainless Steel, with spring 1C001324EM4V 2

T-Nut, M6, Stainless Steel, with spring 1C001324EM6V 2

Pulsation dampener, 2 liter(122cu in) HY00HX2F-00 1

Junction Block, electrical, 12 connector JCPCNS000001-00 1

Flowmeter, Coriolis FL00FDSS2A 0

Cable, 3m, for Flowmeter, Coriolis LE00FDSCB3 3

Valve, Solenoid, Flush cycle (same for both valves) VA00NMR1C2 1

Pump, Centrifugal PU00CME0305ASGE 1

Seal Repair kit, Pump SM0096932440 1

I/P Regulator, Proportional, 24VDC VC00MPPE18-06 1


PO Box 7901 – Wheaton, IL 60189-7901 1-866-321-2250

11) Warranty Information

Warranty is (1) year on parts from ship date, excluding normal wear items. Seller warrants that the products do not infringe upon any copyright, patent, or trademark. THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THOSE CONCERNING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

2850 owner's manuals-manual.pdfpower: 120 vac, 7 amp 200-240 vac, single phase, 4 amp air: 5-6...

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