Spraying Systems AutoJet 2850+ Owner's Manual
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Spraying Systems AutoJet 2850+ Owner's Manual

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2850+
Spray Control Panel
OWNER'S MANUAL
ML002850PLUS
spray.com

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Summary of Contents for Spraying Systems AutoJet 2850+

  • Page 1 ® AutoJet 2850+ Spray Control Panel OWNER’S MANUAL ML002850PLUS spray.com...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1 Preface ·································································· 3 8 Alarm Settings ····················································· 31 1.1 Important ·························································· 3 8.1 Overview ························································· 31 1.2 How To Use This manual ··································· 3 8.2 Liquid Pressure Alarm Setup ··························· 31 2 Safety ···································································· 3 8.3 Atomizing Air Pressure Alarm Screen·············· 32 2.1 General Safety Information·······························...

  • Page 3: Preface

    This manual is intended to be a source of information for the operators and technicians who may be installing, inter- acting with or servicing/maintaining Spraying Systems Co.® systems and components. This manual contains important safety warnings, installation instructions, operating instructions, troubleshooting and maintenance information.

  • Page 4: Unpacking The System

    USE OF CHEMICAL COMPONENTS Spraying Systems Co. does not manufacture or supply any of the chemical components used in this equipment and is not responsible for their effects. Because of the large number of chemicals that could be used and their different chemical reactions, the buyer and user of this equipment should determine compatibility of the materials used and any of the potential hazards involved.

  • Page 5: Panel Overview

    SECTION 3 PANEL OVERVIEW 3.1 OVERVIEW The 2850+ Control Panel contains a PLC, power supplies, relays, fuses, and more equipment for advanced spray con- ® trol and operation. The 2850+ control panel can support up to 16 PulsaJet nozzles per channel, up to 2 channels. Op- tional I/P air regulation for various methods of open and closed loop control.

  • Page 6: Panel Controls

    3.2 PANEL CONTROLS 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 otherwise, the reset buttons, are not used under normal operating conditions.

  • Page 7: Interior Panel Components

    3.3 INTERIOR PANEL COMPONENTS The electrical panel houses the spray controller, electronically controlled current to pressure converters (I/P), PLC, ethernet switch, power supplies and zoning modules. Ethernet Switch 2008 Modules Power Supplies I/P Proportional Regulator Network Module Solenoid Valve Item Description / Function Power Supply (Standard) 24V 10A power supply standard.

  • Page 8: User Passwords And Modbus

    3.4 USER PASSWORDS AND MODBUS USER PASSWORDS Description Username Password Operator OPER Engineer MODBUS TAGS PLC Tag Name Variable Address Type HMI_SPRAY_EN_CH1 BOOL 000001 ALARM_HORN BOOL 000002 CH1_LEVEL_SENSOR_ALM BOOL 000003 REM_CH1_RUN_INPUT BOOL 000100 REM_CH2_RUN_INPUT BOOL 000101 HMI_LIQ_PRESS_CH1 REAL 300001-300002 HMI_CH1_FM REAL 300003-300004 CH1_LINE_SPEED...

  • Page 9: Operation Screen

    SECTION 4 OPERATION SCREEN 4.1 HMI TOUCH PANEL OPERATIONS Operating Screen The 2850+ Menu Button in the top right corner is used to open the navigation menu. Navigates to Main Screen as seen on start-up. Use during regular operation to toggle between Standby and Run modes, change recipe and observe setpoints and current values.

  • Page 10: Operating Screen

    4.2 OPERATING SCREEN Item Description Active Zone Recipe (read only) The current zone being operated, if zoning is active, is displayed here. Frequency (read only) The spray gun operating frequency is displayed here. Application Rate (read only) The current application rate output by the 2850+ based on flow and user input density.

  • Page 11: Recipe Setup

    SECTION 5 RECIPE SETUP 5.1 RECIPE SCREEN OPERTIONS Item Description These arrows allow for the selection of the recipe displayed and available to be edited. Recipe # (selection) Please be aware this can change during operation. Recipe Name Allows the user to associate a character string with each recipe number. This recipe name (editable) will appear on the operating screen as the active recipe to assist the operator.
  • Page 12 # of Triggers Trigger: The system will spray while the start trigger is held high. (selection) Trigger/Reset: The system will spray continuously after the start trigger is held high mo- mentarily. The spray is stopped by holding the reset trigger momentarily. Recipe # (selection) This menu allows for the selection of the recipe being used by the controller.

  • Page 13: Nozzle Configuration

    5.2 NOZZLE CONFIGURATION The Nozzle 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. Use the channel specific page to adjust the nozzle settings for the correct channel. Nozzle Configuration Screen Item Description...

  • Page 14: Timing And Spray Settings

    SECTION 6 TIMING AND SPRAY SETTINGS 6.1 PRECISION SPRAY CONTROL (PSC) The PulsaJet® automatic spray nozzle is an electrically-activated hydraulic, atomizing nozzle. This nozzle sprays the product in a controlled way using a PWM algorithm to control the sprayed amount without affecting the spray angle. PWM is the fundamental control principle that allows a significant reduction in flow by regulating the relationship between the on/off times that the nozzle operates.
  • Page 15 CYCLE SPEED The maximum frequency parameter (f ) determines the maximum speed of the nozzle at 50% duty cycle and is entered as a number of cycles/minute. This parameter can be found in the datasheet of the electric spray nozzle being used.

  • Page 16: Spray Timing Modes

    DISTANCE BASED SPRAY TIMING The fixed and variable spray length timing modes have an alternative in which distances are used instead of time. These modes are called fixed spray distance and variable spray distance. In these modes, delays are expressed in distance units.
  • Page 17 ANTICIPATOR PRIORITY By default, the system gives priority to the start delay, potentially resulting in a too short or a zero-anticipator time, which may negatively impact the spray pattern if the start delay is too short. In this case, the start delay will be ex- tended as required to provide a correct anticipator time.
  • Page 18 FIXED SPRAY TIME - WITH REPEAT This timing mode is used to create a continuous repetition of spray period for a fixed time. Note: See Configuration settings or Recipe Settings for more information on Timing Mode setup. Repeat Spray: The system can generate a repeating pattern inside of a spray period. Repeat Spray Special Case: Repeat Spray, Air Overlap: If repeat off-time <= (anticipator + follower time), the air will remain on.

  • Page 19: Variable Spray Timing

    6.5 VARIABLE SPRAY TIMING This timing mode is used to create spray pulses with variable length. The lengths of the spray pulses depend on the specific time delays between the rising and falling edge of the trigger input. Variable Spray Time PARAMETER VALUE Start Delay...
  • Page 20 DECREASING SPRAY LENGTH The spray length can be decreased by: • Increasing the Start Spray Delay: the spray is started after the object is already under the spray nozzle. In this case the beginning of the object is not sprayed •...
  • Page 21 OBJECTS TOO SMALL If spray events overlap, the overlapping event will be ignored, and the system will skip the small object. This situation may occur when the following is true: • Stop spray delay < Start spray delay • Object size < (start delay – stop delay) Variable spray period - objects too small DISTANCE DELAY, MAXIMUM SPRAY PERIOD This timing mode is used to create a delayed spray pulse of an unknown period when receiving a trigger signal.
  • Page 22 VARIABLE SPRAY LENGTH—WITH REPEAT This timing mode is used to create a continuous repetition of spray pulses for a variable time. The duration of the repetition depends on the specific time delays between the rising and falling edge of the trigger input. Variable spray length with repeat diagram PARAMETER VALUE...

  • Page 23: Configuration Screens

    SECTION 7 CONFIGURATION SCREENS ATTENTION: Channel 1 and Channel 2 screens contain identical fields and options except where noted. 7.1 SYSTEM CONFIGURATION Press the boxes to open a secondary screen with editable fields for each feature. 7.2 CH1 LINE SPEED SETUP System Configuration Screen Item Description...

  • Page 24: Ch1 Liquid Pressure Setup

    7.3 CH1 LIQUID PRESSURE SETUP Liquid Pressure Setup Screen Item Description Liq Press 1 Displays the channel 1 liquid pressure Liquid Pressure Selects the method of liquid pressure feedback for control loops. (selection) Not Installed: There is no liquid pressure sensor installed. Certain features will not be ena- bled as they require liquid pressure feedback.
  • Page 25 CH1 LIQUID PRESSURE PID The graph is a trend of the liquid pressure setpoint and process value versus time. Item Description Liquid Pressure CTRL OPEN LOOP Toggles liquid pressure PID on/off for specified channel (on/off) CH 1 Standby Toggles Channel 1 between ‘Run’ and ‘Standby’ modes. Liq Pressure Setpoint (display) Displays desired liquid pressure (PSI).

  • Page 26: Ch1 Atomizing Air Pressure Setup

    7.4 CH1 ATOMIZING AIR PRESSURE SETUP Item Description Atom Air Press 1 Displays the channel 1 atomizing air pressure (editable) Atom Air Press Selects the method of atomizing air pressure feedback for control loops. (selection) Not Installed: There is no pressure sensor installed in the atomizing air line. Certain features will not be enabled as they require liquid pressure feedback.

  • Page 27: Ch1 Flow Meter Setup

    7.5 CH1 FLOW METER SETUP Item Description Flow Meter 1 Displays the channel 1 flow rate. (editable) Flow Meter Selects the method of flow rate feedback for control loops. (selection) Not Installed: There is no flow meter installed. Certain features will not be enabled as they re- quire liquid pressure feedback.
  • Page 28 CH1 FLOW RATE PID Item Description Flow Rate PID OPEN LOOP (on/off) Toggles Duty Cycle PID on/off for specified channel Flow Rate SP (GPM) (read only) Display desired flow rate setpoint. Flow Rate PV (read only) Display of the current flow rate. Flow Rate CF (editable) The flow rate correction factor is determined by running the PID in closed loop.

  • Page 29: Remote Setpoint Setup

    CH1 APP RATE PID Item Description App Rate PID OPEN LOOP (on/off) Toggles App Rate PID on/off for specified channel Flow Rate PV (GPM) (read only) Display of the current flow rate. App Rate SP (mL/SQ FT) (read only) Display desired app rate setpoint (mL/sq. ft.). App Rate PV (mL/SQ FT) (read only) Display of the current flow rate.

  • Page 30: Header Info

    Item Description Analog INP 1 (read-only) Displays the current analog input 1 reading Span (editable) Set the 20 mA reading on the 4-20 mA scale for analog input 1 Analog INP 2 (read-only) Displays the current analog input 2 reading Span (editable) Set the 20 mA reading on the 4-20 mA scale for analog input 2 Ch1 Ethernet Rem SP (read-only)

  • Page 31: Alarm Settings

    SECTION 8 ALARM SETTINGS 8.1 OVERVIEW Alarm settings page sets the condition that will cause an alarm by the PLC. Each button will open a secondary screen with options for each alarm. Each alarm can either be enabled or disabled. By default, every alarm is disabled, and editable fields are set to zero.

  • Page 32: Atomizing Air Pressure Alarm Screen

    8.3 ATOMIZING AIR PRESSURE ALARM SCREEN Item Description Ch1 AAIR Press Alarm (toggle) Enables or disables the atomizing air pressure alarm. Min Pressure (editable) Sets the minimum pressure allowable before alarming. Max Pressure (editable) Sets the maximum pressure allowable before alarming. Tolerance Time (editable) Sets the maximum allowable time outside the max or min pressure.

  • Page 33: Pwm Alarm Setup

    8.6 PWM ALARM SETUP Item Description Ch1 PWM Alarm (toggle) Enables or disables the PWM alarm. Tolerance Time (editable) Sets the maximum allowable time outside the recommended duty cycle percentages before alarming. 8.7 SHOT VOLUME ALARM SETUP The Shot Volume Alarm operates by observing the ratio of shots outside of the desired volume to the total number of shots.

  • Page 34: App Rate Alarm Setup

    8.8 APP RATE ALARM SETUP Item Description Ch1 App Rate Alarm (toggle) Enables or disables the application rate alarm. Low Percentage (editable) Sets the minimum percentage of application rate allowable before alarming. This percentage is based off the setpoint in the active recipe. High Percentage (editable) Sets the maximum percentage of application rate allowable before alarming.

  • Page 35: Monitor I/O Settings

    SECTION 9 MONITOR I/O SETTINGS 9.1 MONITOR I/O The Monitor IO menu option from the 2850+ menu allows the user to see sev- eral screens which provide live readings of both the analog and digital aspects of the PLC. These screens are extremely useful for troubleshooting whether or not sensors are working as the values displayed are irrespective of settings...

  • Page 36: Clean/Purge Settings

    9.4 CLEAN/PURGE SETTINGS The Clean/Purge screen allows the user to configure and control clean/purge cycles. Item Description Ch1 Purge (editable) Purges the fluid lines before an initial run of air ensuring nozzles are full of fluid. Ch1 Clean (editable) Pressing this button engages the clean process using the parameters set for the given channel.

  • Page 37: Help Settings

    SECTION 10 HELP SETTINGS 10.1 HELP SCREEN Information such as vendor revision and serial number of the 2008 can be found in the help screen. The HMI-OS tab allows the user to visit the setup screen for the HMI. If the HMI starts to lag, it can be useful to visit this screen and re- set the power to the HMI by using the power button in the top right of that screen.

  • Page 38: Troubleshooting And Faults

    SECTION 11 TROUBLESHOOTING AND FAULTS 11.1 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 power supply voltage 24vdc (21vdc-29vdc).
  • Page 39 Alarm Mes- Cause Potential Fixes sage CH1/CH2 App The application rate on channel 1 •Check that the line speed reading is correct on the operating screen Rate Alarm has deviated outside the user set •Navigate to Ch1/2 Sensor configuration screen and check that linespeed is tolerance range for the user configured correctly specified tolerance time.
  • Page 40 However, Spraying Systems Co. assumes no liability for errors or omissions and reserves the right to make changes without notice to any products described herein to improve reliability, function, or design. Other company and product Warranty is one (1) year on non-wear parts from ship date.

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