TABLE OF CONTENTS 1. Preface ········································································································································ 3 1.1 Important ········································································································································ 3 1.2 How To Use This Manual ················································································································ 3 2. Safety ·········································································································································· 3 2.1 General Safety Information ············································································································ 3 2.2 Unpacking The System ···················································································································· 4 3. System Overview ························································································································· 5 3.1 Introduction ····································································································································...
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.
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.
3.1 INTRODUCTION The Spraying Systems Co. ES2500 is an Electrostatic System that utilizes a low flow rate and negatively charged fluid to produce electrostatic spraying. The system’s purpose is to deliver a controlled spray with a very high transfer efficiency. System applica- tions include spraying various oils and other coating or lubricating fluids onto neutrally charged and grounded metallic targets.
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HOLLOW SHAFT ENCODER Calculating the calibration constant—K Factor (pulses/ft) K = PPR / CIR (ft.) = PPR / (PI*DIA) *Use diameter of drive/tail pulley that encoder is attached to. K = PPR (*D1/D2) / (PI*D2) *Used with dual pulley configuration. D1—Drive/Tail pulley, D2—Secondary pulley encoder is attached to. Gear ratio = D1/D2 SPECIFICATIONS Resolution (PPR)
SECTION 4 CONTROL PANEL 4.1 Control Panel Overview The ES2500 Control Panel is used to adjust the parameters of the manifold and adjust the settings on the fluid delivery cart. Using the HMI screen settings you can adjust the operation and configuration settings. PANEL POWER REQUIREMENTS : Voltage–...
4.2 HMI OVERVIEW The HMI screens are shown with additional features or options that may not be included with your system configuration. First starting up and after any system reboot, the Operating screen will load as the system default screen. From the ‘Operating’...
4.3 PURGE/CLEAN SETTINGS The ‘Purge/Clean’ features allows for pump operation and liquid flow without the activation of the High Voltage Pow- er Supply (HVPS) and Electrostatic components. PURGE The purge function purges the fluid lines of air by running the pump to fill the lines with fluid. Purge mode should be run until fluid begins to drip from the manifold nozzles.
4.5 RECIPE SETUP The Recipes feature allows you to create and save your commonly used spray parameters. The system supports the creation and storage of up to 16 customized recipes. Switching between premade Recipes allows for much quicker transitions when changing batches or products that may require different spray parameters. Each individual recipe allows you to: •...
4.7 CH1 CONFIGURATION CH1 HIGH VOLTAGE FEEDBACK SETUP Note: Ch2 configurations setup are the same as Ch1 con- figuration setup. The operator can set the max voltage output in kV for both the HVPS and PLC. CH1 LINE SPEED SETUP If you are using a line speed encoder with the ES2500, this con- figuration will allow you to use the device with the system.
4.8 MOTOR/DRIVER INFORMATION The Pump Motor and Drive Information section provides operators with current operational information for the system motor and sets certain system parameters and view/reset the trip meter. It allows the operator to set the degrees per step (Deg Per Step) and the milliliters per revolution (mL/Rev) for the pump.
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ALARM HISTORY SCREEN The Alarm History screen allows operators to view any ongoing or past alarms. This screen will log the time that an alarm occurs, as well as the specific alarm fault code. ALARM SETTINGS Alarm settings allows operators to adjust the parameters for system alarms. Most alarms have tolerance times that are user-controlled settings.
4.10 MONITOR IO SETTINGS When Monitor IO is selected from the Navigation menu, the first screen you will see is “Embedded IO Monitor” as seen below. This screen provides live readings of both the analog and digital aspects of the PLC. This screen can pro- vide useful information when troubleshooting system components.
ANALOG IO The Analog IO screen displays current analog values for the controller, which can be useful for troubleshooting pur- poses. 4.11 HELP SETTING Selecting ‘Help’ from the navigation menu will bring up a screen that displays system information, access the HMI OS, Screen Map, and change password profiles.
SECTION 5 FLUID DELIVERY CART 5.1 OVERVIEW The fluid tank features a level sensor to monitor and produce a fault when the Fluid Tank fluid falls to a low level. The tank also features a 3-way ball valve at its outlet for fluid draining and cleaning purposes.
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PROGRAMMING THE LEVEL SENSOR The tank level sensor comes pre-programmed. However, the set points (Q1 – SP1 and Q1 – RP1) can be adjusted to configure the system specifically for the application. The level sensor displays the tank level as a percent (%) full. However, all parameters are measured in millimeters (mm) from the bottom of the probe.
SECTION 6 MANIFOLD 6.1 OVERVIEW In electrostatic spraying, a negative charge is introduced into the fluid in the manifold body via a central charging elec- trode. This causes the liquid to become negatively charged, which will then cause the fluid molecules to repel each other.
6.3 HOOK-UP FLUID LINE Tubing must be made from a material that is compatible with fluid to be sprayed, as well as rigid enough to work with the 1/4” OD tube push-to- connect fittings that are supplied with nozzle assembly. ATTENTION: Metallic tubing is not to be used as it will in- terfere with the electrostatic fields and skew the spray or potentially trip the AccuJet Electrostatic Controller.
GROUND WIRE The ground wire assembly should come connected to the ground rods with 7/16 hex head bolts on each end of the conveyor nozzle assembly. The ground wire assembly should be connected directly to an earth ground as defined by local electrical codes.
6.5 NOZZLE CONFIGURATION 1. Start with the nozzle body slide all the way down to the end blocks and with the ground rods moved as far out from the nozzle body as possible. 2. Position the manifold so that nozzle spray tube tips are 8” above the target with tubes pointing straight down. 3.
At this point, the run function can be turned on by returning to the ‘Operating’ screen and selecting ‘run’. 10. Flip the CH1 trigger switch on the panel door to the right. Note: An external trigger can be connected to the system for remote activation. 13.
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STEP 3 Remove the end cap and sanitary gasket from the end opposite of the elec- trode. With the end cap and sanitary gasket removed, the electrode end bush- ing is now visible. Turning the nozzle upright, the electrode end bushing and electrode should fall out.
SECTION 8 TROUBLESHOOTING If troubleshooting steps are followed and the system still does not function, please contact your local Spray Specialist or call 1-800-95-SPRAY (1-800-957-7729). If any system/component malfunctions occur, shut off the system immediately and perform the following steps: •...
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No fluid at spray nozzles Cause: Solution: Improper pump adjustment Adjustment pump flow by changing the setting in the recipe Damaged or leaking lubricant lines Inspect, identify, and replace lines Clogged or leaking pump Clean or replace pump Clogged spray nozzle(s) Flush spray nozzle with hot water/detergent solution.
Fault Cause Remedy • 1 or (2) CH1 (CH2) COLTAGE Detects if there is a broken wire in Check the panel wired connections • MONITOR NOT WIRED the panel, or a possible faulty power Replace power supply if needed supply •...
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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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