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Spraying Systems Co AutoJet 2150+ Owner's Manual

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OWNER'S MANUAL
ML002150PLUS
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Summary of Contents for Spraying Systems Co AutoJet 2150+

  • Page 1 ® AutoJet 2150+ Spray Control Panel OWNER’S MANUAL ML002150PLUS spray.com...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1. Preface ······································································· 3 9. Speed/Encoder (Option) ··········································· 39 1.1 Important ··························································· 3 9.1 Speed/Encoder ·················································· 39 1.2 How To Use This Manual ··································· 3 9.2 Encoder Selection ·············································· 40 2. Safety ········································································· 3 9.3 Encoder Spare Parts ·········································· 41 2.1 General Safety Information ·······························...

  • Page 3: Preface

    This system has been designed with components that work together to provide the best system performance. When ® replacement parts are required, only Spraying Systems Co. recommended components should be used to maintain proper system operation, electrical and pneumatic safety. The use of any unauthorized replacement parts will void any warranties.

  • Page 4: Unpacking The System

    All phases of equipment installation must comply with federal, state, and local codes. PERSONAL PROTECTIVE EQUIPMENT Spraying Systems Co. strongly recommends the use of appropriate safety equipment when working in potentially hazardous environments or with potentially hazardous chemicals. This safety equipment includes, but is not limited to, the following: •...

  • Page 5: Overview

    SECTION 3 2150+ OVERVIEW The 2150+ is the advanced level offering in the Spray Control System (SCS) Series. It provides ON/OFF timing control and liquid pressure control for both electrically- and pneumatically-actuated spray nozzles. The system comes in a variety of design configurations depending on the spray application, therefore, you may or may not have all the features described in this owner’s manual.

  • Page 6: Precision Spray Control (Psc)

    SINGLE CHANNEL SPECIFICATIONS: • • 48V nozzle driver (Standard) 7” HMI Touch Screen control and display —48Vdc/10A power supply —HMI window kit (optional) • • 24V nozzle driver (Optional) Wall mountable stainless steel enclosure, washdown with door closed —24Vdc/10A power supply —Power ON/OFF switch-Power on indicator light DUAL CHANNEL —Power cord, 6ft (2m) length...

  • Page 7: Position Or Mount The System

    3.4 POSITION OR MOUNT THE SYSTEM The system should be placed in a convenient location near the spray application. A properly grounded power outlet must be easily accessible. —Determine if the unit will be free-standing or wall mounted. CONTROL PANEL ONLY VERSION Note: The Control Panel Only version should be wall mounted.

  • Page 8: Remote Connection

    3.6 REMOTE CONNECTION Users can connect to the 2150+ with a mobile device via Wi-Fi to create an access point. Once set-up is complete, you can adjust settings, view alarms, troubleshoot, review maintenance schedules, and more on the connected mobile device.

  • Page 9: Hmi Operations-Set Spray Parameters

    3.8 HMI OPERATION—SET SPRAY PARAMETERS 1. Set the system to manual mode. Disconnect the nozzles. Set all pressure regulators to 0. Turn on the main air pressure and increase liquid pressure gradually to flush the system. Everything is now flushed except for the nozzles.

  • Page 10: Home Screen

    SECTION 4 2150+ HOME SCREEN 4.1 HOME SCREEN—CHANNEL A AND B The 2150+ is available in either a single or dual channel configuration. In a single channel system, there will be no channel name or designation shown on the home screen. In a dual channel system, the Channel A label will be visible in the lower left corner of the screen and under the top bar.

  • Page 11: Home Screen Options

    4.2 Home Screen Options The home screen at the top and side bars will always be visible and accessible. Setpoint: Displays the configurable mode in the application you are set in. Nozzle status: Displays the current nozzle spray status as a percentage of the maximum flow rate. Atomizing air status: Atomizing Air Status and spray status are read-only representations of the current status.

  • Page 12: Purge And Clean

    4.3 PURGE AND CLEAN Purge and clean cycles can be toggled on or off with their labeled On/Off indicators at the bottom of the screen. A blue indicator with the dot on the right side shows the currently selected and active cycle. Purge and Clean settings screen PURGE The purge cycle is commonly used to empty the fluid lines of liquid, or as an additional way to drain a tank or pressure...

  • Page 13: General Settings

    SECTION 5 GENERAL SETTINGS General settings relate to the spray control panel itself and how operators interact with the 2150+. 5.1 SETTINGS SCREEN The 2150+ allows operators to manage users and user settings, change the language (where applicable), view system information, and view the activity log.

  • Page 14: User Management Settings

    ACTIVITY LOG The 2150+ tracks all changes to critical settings and records which users make these changes; this information is available in the activity log. Users within the User Group cust_admin can view these activity reports on the 2150+ or export the activity report via a USB stick.
  • Page 15 ADD USER EDIT USER Create a new user and assign them to a User Group. Ensure Edit the selected user’s properties. You can change the that you use the drop-down menu to pick the correct user user’s password for them, or change their User Group. group.

  • Page 16: User Groups

    5.3 USER GROUPS The system contains four preloaded users (username and password sets) that are the factory (default) settings. Users can choose to use (or edit) these existing users or create new users as they see fit. Each of these default users has a different level of user rights to interact with the system based on their selected User Group.

  • Page 17: Supplying Air To The System

    It is not regulated; therefore, you must provide a minimum of 45 psi (3.1 bar) to the ® system. It must be above 45 psi (3.1 bar) to actuate air actuated nozzles like Spraying Systems Co. 1/4JAU series.

  • Page 18: Application Settings

    SECTION 7 APPLICATION SETTINGS Application settings allow you to customize the spray parameters to achieve the desired spray coverage and flow rates. These settings will also allow you to configure certain 2150+ accessories, such as the pressure sensor, flow meter, or line speed encoder.
  • Page 19 Selecting Nozzle Type: —Nozzle Family: Select the type of nozzle supplied with the system. —Enable Atomizing Air if required. —Advanced nozzle settings allows for editing the PWM Waveform settings. Editing nozzle type ANTICIPATOR/FOLLOWER TIME The system will start spraying when it receives a trigger signal and stop when the trigger signal is removed. If the system is equipped with an air atomizing nozzle, the 2150+ will switch the air output on before it starts spraying to allow the spray pattern to develop fully.
  • Page 20 PARAMETERS—ADVANCED NOZZLE SETTINGS For custom applications, it is possible to change the properties of the nozzle manually. These settings should only be modified by instruction from qualified SSCO personnel except for the nozzle cycle count. WARNING: Incorrect settings can permanently damage the spray nozzle! Negative Pulse: Pulse time in milliseconds •...
  • Page 21 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 22: 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 23 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 extended as required to provide a correct anticipator time.
  • Page 24 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 25: Variable Spray Time

    7.4 VARIABLE SPRAY TIME 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 26 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 27 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 28 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 29: Configuration

    7.5 CONFIGURATION Configuration settings allow you to set timing and setpoint spray parameters. Configuration will only appear when a system configuration does not include recipes. If the system configuration includes recipes, the button will display “Recipes” and will take you to the recipes screen. Note: If you have recipes: see Recipes section for detailed information about Timing and Setpoint settings.
  • Page 30 DUTY CYCLE Operates by allowing the user to set the desired percentage control for the cycle rate. Set the other values as desired to establish the duty cycle. Fluctuations in the spray pressure will be monitored by the 2150+ (with connected pres- sure sensor) and real-time adjustments to the setpoint will be made.

  • Page 31: Recipe Settings

    7.6 RECIPE SETTINGS Recipes can be accessed quickly from any screen by selecting the recipe section of the top bar, as shown in the image below. Recipe Settings screen The recipe settings sections contains four tabs. The drop down list near the top of the page allows you to select which recipe you would like to view, edit, or apply as the current spray parameters.
  • Page 32 TIMING TAB The Timing tab sets all of the timing-related parameters for your recipe. Use the drop down menu to select the timing mode, then set all of the timing values. See section 2150+ Spray Timing Modes for more information. Editing values in the Timing tab Recipe settings.

  • Page 33: Duty Cycle

    7.7 DUTY CYCLE Duty cycle represents the ratio of the spraying "on" time to the "off" time, which results in some percentage of the maximum possible (continuous) flow through the nozzle. The duty cycle settings allow you to select the source and enter sensor default values.
  • Page 34 ASSEMBLY SPECIFICATIONS: Color Code: Duty Cycle Pin# Color Description Brown +24 VDC White If the 0 VDC is coming from a pow- Blue 0 VDC er supply outside of the panel (PLC), connect it to this wire—#3 Black 4-20mA • Panel connection: 4-20mA •...

  • Page 35: Trigger

    7.8 TRIGGER If you have an external trigger source, select the correct and corresponding option for the external trigger from the drop down list. Toggling the “Inverted” option to the On position will allow the use of a trigger that sends a signal when off rather than when on.

  • Page 36: Tank Level Sensor

    7.9 TANK LEVEL SENSOR If your configuration includes a pressure pot with a level switch, select the edit button and use the drop down menu to activate the level sensor signal. Once turned on the 2150+ can now see the low level condition. Color Code: Tank Level Sensor Color Description...

  • Page 37: Pressure Sensor (Option)

    SECTION 8 PRESSURE SENSOR (OPTION) 8.1 LIQUID PRESSURE (PRESSURE SENSOR) Liquid Pressure settings require an active pressure sensor connection to the 2150+. When connected, the input settings are to be calibrated to match the specifications of the pressure sensor. Pressure sensor settings screen Actual: displays the current live readings from the pressure sensor.

  • Page 38: Pressure Sensor Spare Parts

    STANDARD PRESSURE SENSOR Do not use the standard pressure sensor with fluids containing solids. • Measuring range: 0-100 psi • Connection type: 1/2” NPT (male x female) • Protection rating: IP67/IP69K • Cable details: M12 (M) - 5m FLUSH-STYLE PRESSURE SENSOR Use the flush-style pressure sensor with fluids containing solids.

  • Page 39: Speed/Encoder(Option)

    SECTION 9 SPEED/ENCODER(OPTION) 9.1 SPEED/ENCODER KIT The encoder kit can be used with the Application Rate Setpoint to control the system with units of distance instead of timing. Speed/Encoder settings require a connected line speed encoder. Plug and Spray connections, encoder (located on bottom of 2150+) SPEED SETTINGS •...

  • Page 40: Encoder Selection

    9.2 ENCODER SELECTION With the 2150+, you can select either the hollow shaft or wheel and pivot mounted style encoder. The hollow shaft style will mount into the conveyor, while the wheel and pivot style requires the wheel to rest on the conveyor surface to measure the line speed.

  • Page 41: Encoder Spare Parts

    9.3 ENCODER SPARE PARTS Pivot Mount Encoder Part Part Number Pivot Mount with hardware EN001113280001 12” circumference measuring wheel, Phenolic w/ 3/8” bore EN001600 1024 ppr, 5-26 VDC input, 5-26 VDC push/pull output, 5-pin M12 connector, EN00221025B546 3/8” single shaft w/seal Five-meter cable with M12 (f) connectors LEXXSD4FD4F0050 Hollow Shaft Encoder...

  • Page 42: Flow Meter(Option)

    SECTION 10 FLOW METER(OPTION) SINGLE AND DUAL CHANNEL ADD ON The SCS Series flow meter is mounted on a plate. With a single channel 2150+, you will receive the standard single channel flow meter. If you have a dual channel 2150+, you will receive the standard single channel flow meter with a second channel add-on.

  • Page 43: Assembly Specifications

    INPUT SETTINGS • Sensor Scaling: Adjusts the controller to match the output of the sensor. • Sensor mode: Off (not using flow meter), Flow -- No Alarm, and Flow -- With Alarm. • Sensor Value at Offset: The minimum value of GPM that offsets the starting point that controls pressure sensor. •...

  • Page 44: Flow Meter Spare Parts

    10.3 FLOW METER SPARE PARTS Flow Meter Part Part Number Cable Glands, Strain Reliefs & Cord Grips LTCG 3/4 NPT 8.5mm SPLIT BLACK CG00836M3234GBH Flow Sensor Controller: Main Unit, DIN Mount for FD-X series FL00FD00XA1 Clamp, Metal Pipe, 10.8mm - 14mm, 1/2" ODT, for use w/ FD-XS20 FL00FDXC20M2 Flowmeter, Ultrasonic, Sensor Head, 0 - 20000 mL/min, clamp on, 2m cable, FL00FDXS20...

  • Page 45: Maintenance And Troubleshooting

    SECTION 12 MAINTENANCE AND TROUBLESHOOTING 12.1 MAINTENANCE AND TROUBLESHOOTING SETTINGS The 2150+ is equipped with an internal maintenance scheduler. This allows you to create and set Preventative Maintenance (PM) events. These events can include anything from routine cleanings to specific events like component repair or replacement.
  • Page 46 Parts can be selected from the drop down list. Once selected, a part description can be viewed or edited. ® The contact information for your local Spraying Systems Co. Spray Specialist can be found by selecting the Spray Specialist tab. These editable boxes contain the name, phone number and email address of your Spray Specialist.

  • Page 47: Diagnostics

    14.1 ELECTRIC NOZZLE CORD SET ® If the system is designed to operate Spraying Systems Co. PulsaJet or AA250 electric actuated spray nozzles, the system is supplied with a cord to connect the spray nozzle to the Control Panels. All the electric actuated nozzle cord sets are wired as shown in the diagram.

  • Page 48: Trigger Cable

    14.2 TRIGGER CABLE Optional trigger cable offering: Un-terminated flying lead cable and connector. REQUIRED INPUT • Part number - LE00M12F5M – M12(f) x bare lead trigger cable • NPN – Switch to 0 VDC to turn on spray trigger.  Requires NPN Sensor or dry contact switch.

  • Page 49: Color Sensor

    14.4 COLOR SENSOR Full-Spectrum color, detects color/brightness/surface finish/intensity, NPN/ PNP, IP65/ IP67 rating, 1.18 to 19.69 in. detectable distance. 14.5 PROXIMITY SENSOR For sensing metallic objects. Kit includes sensor, with mounting nuts and locking washer, and cable. SPECIFICATIONS: Proximity sensor – Detects all metals 10mm max. sense dist., 24vdc, NPN outputs N.O./N.C., shielded, IP67, 5m cable wired •...

  • Page 50: Hand Trigger Pendant

    14.8 HAND TRIGGER PENDANT For manual triggering of the system. The unit offers two switches to independently trigger the system. Cable length offers flexibility in location of operation. SPECIFICATIONS: • Part number: SW001550M12HT • 2 Switches  1 - On/Off selector switch ...

  • Page 51: Laser Sensor (Short)

    14.10 LASER SENSOR (SHORT) For accurate short distance sensing of objects (thin, shiny, dark, clear, multi-faceted) SPECIFICATIONS: Laser sensor – with cable, connector, and bracket. • Kit number: 040TS04000135W0 • NPN – NO + NC • 1.0” – 3.5” [25mm – 90mm] sensing range (1.5mm – 3mm deviation range). •...

  • Page 52: Fault Output Cable Kit

    Fault Output Signal Kit 040TS04000054W0 14.13 FAULT OUTPUT CABLE KIT The 1750+ and 2150+ offer a feature to provide a signal when a fault has occurred during operation. This is wired as shown in the table below. To use this feature, you need to have our optional splitter cable kit. •...

  • Page 53: Extension Cable

    14.14 EXTENSION CABLE If longer length cables are required, an extension cable is available that can be used to go between the nozzle cable and the junction block or the junction block cable and the system. This cable can also be used to extend the trigger device cable lengths.

  • Page 54: Level Sensor Input

    14.16 LEVEL SENSOR INPUT A level switch (any normally open or normally closed float switch) can be wired to the system, so when the tank level drops below a certain level, a fault will be shown on the HMI. Wire the level sensor/float switch to the panel utilizing the cable shown below. You will only use the black and blue wires (dry contacts - polarity not important), carefully cut back and tape the brown and white wires.

  • Page 55: Faults And Troubleshooting

    SECTION 15 FAULTS AND TROUBLESHOOTING FAULT CAUSE SOLUTION Check Wiring, Verify sensor is receiving power. Check Liquid Pressure Sensor Wire break detected cable continuity. Remote 4-20mA setpoint wire Check Wiring, Verify sensor is receiving power. Check 4-20mA Remote Setpoint break detected cable continuity.
  • Page 56 FAULT CAUSE SOLUTION External 1 Fault 1 triggered remotely Custom faults, See internal systems controls for details External 2 Fault 2 triggered remotely Custom faults, See internal systems controls for details Unexpected trigger check signal Trigger Check Sensor 1 Verify trigger is operating at rated specifications. received Trigger check Signal was not Trigger device signal is not long enough.
  • Page 57 • Controller will not power up, yet main power indictor light (red LED near power switch) DOES illuminate. —Follow these steps to check power connection on the HMI: ) Unplug the system. ) Carefully open the panel. Take care to not put stress on the wires or scratch the HMI screen. ) Ensure that there are no loose wires in the system.

  • Page 58: Internal Components

    15.1 INTERNAL COMPONENTS Internal Wiring Level Switch Spray Status Trigger Encoder SYNC Output Run/Standby Duty Cycle Pressure — Remote Setpoint Di-select NPN vs. PNP Flow Meter 24V/0V 24V/0V — PWM +/- PWM Output Fault VIN +/- Power Supply...

  • Page 59: Ethernet Ip Manual (Optional)

    SECTION 16 ETHERNET IP MANUAL (OPTIONAL) Ethernet I/P control is available as an additional item on the 2150 controller. Ethernet I/P is a communication protocol that allows for easy data transfer from a main controller to auxiliary devices. The 2150 can be controlled and monitored via Ethernet I/P.
  • Page 60 3. Verify the file is the correct format for your installation. Press Next. 4. Verify it is detected as a CompactCom 40 EtherNet/IP type. 5. Once verified, register the EDS file. 6. Press Finish to complete.

  • Page 61: Loading The Registered Eds File

    16.2 LOADING THE REGISTERED EDS FILE After setting up the EDS file, you must import it. Once Imported you will be able to access variables similar to accessing registers in a PLC. These new array tags will be how you control and monitor the 2150 via Ethernet I/P. 1.
  • Page 62 3. Give the New Module a descriptive name and an IP Address that matches the base IP address used on the spray controllers. Default: 192.168.0.XX. 4. You will now find your Input and Out arrays. See Read/Write tables either in the manual or on the HMI for address locations.

  • Page 63: Ethernet Ip Address List: Read Address

    16.3 ETHERNET IP ADDRESS LIST: READ ADDRESS The Read Adresses allow you to monitor the 2150 varialbes such as Nozzle status, Faults, and any additional sensors you have on the system. Below is a list of which tags belong to which arrays. This can also be seen in th Ethernet I/P section on the HMI.

  • Page 64: Ethernet Ip Address List: Write Address

    16.4 ETHERNET IP ADDRESS LIST: WRITE ADDRESS The Write Adresses allow you to control the 2150 via the main controller. This will allow for controls such as starting and stopping the system and changing which recipe is being used. Below is a list of which tags belong to which arrays. This can also be seen in th Ethernet I/P section on the HMI DEFAULT ETHERNET IP PAGE WRITE ADDRESS...

  • Page 65: Bit Numbers, Faults, And Their Descriptions

    16.5 BIT NUMBERS, FAULTS, AND THEIR DESCRIPTIONS The following alarms will be able to be monitored via Ethernet I/P. These will be read is as an integer which will need to be parsed into binary. The bit number corresponds to which faults are active. For example, if Bits 2 4 and 10 are 1 and the rest are zero.

  • Page 66: Spare And Replacement Parts

    SECTION 17 SPARE AND REPLACEMENT PARTS 2150+ Spray Control Panel Part Part Number Bulkhead assembly kit, batch, 2150+ control panel, with sealing gasket and hardware. CP-ENECT2150- D2_CB02 2008+ to Delta HMI, communication cable - 1m, RS485, shielded CP-LECMS0012-10 Sealing Socket Head Screw, 18-8 Stainless Steel with Viton® O-Ring, 10-32 Thread, 5/8" Long FAMM95198A494 AC Fans AC Fan, High Performance, 120x38mm, 115VAC, 131CFM, 22W, 47dBA, 3300RPM, FN00OA109AP11 Dual Ball Bearing, Terminals.
  • Page 67 2150+ SINGLE, DUAL, AND HIGH CAPACITY VERSION REPLACEMENT PARTS 24V Single Channel Part Part Number Series 2300 Spray Controller, 24V version, Ethernet/IP with Modbus 1 file for Channel A CP-CTTMT232I-00_CA01 Cover plate kit, for channel two, 2150+ control panel, with sealing gasket and hardware. CP-ENECT2150-01_CB01 Labels, 2150+ underside, Single Channel versions, Adhesive backed, Black/White..
  • Page 68 Accessory Kits Part Number Photoelectric Object Sensor: Object Sensor Kit, Trig, 5 m cord length, M12 4 pin (F) 040TS04000014W0 Proximity sensor: Detects all metals 10mm max. sense dist., 24vdc, NPN outputs N.O./ 040TS04000118W0 N.C., shielded, IP67, 5m cable wired Thru-Beam Sensor: Trig, 5 m cord length, connector—M12 4 pin female, IP67/IP69K 040TS04000028W0 rating, NPN output...
  • Page 69 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 names may be trademarks of their respective companies.

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