Related Manuals for Spraying Systems Co AutoJet ES250
Summary of Contents for Spraying Systems Co AutoJet ES250
- Page 1 ® AutoJet ES250 Electrostatic Chain Oiler System OWNER’S MANUAL ML00ES250F spray.com...
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Page 2: Table Of Contents
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. ES250 Overview ··························································································································· 5 3.1 Electrostatics Spraying Overview ···································································································... -
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: Es250 Overview
SECTION 3 ES250 OVERVIEW 3.1 ELECTROSTATICS SPRAYING OVERVIEW In electrostatic spraying, a negative charge is introduced into a fluid in the nozzle body through a central charging elec- trode, which causes the fluid to acquire a negative charge. When this negative charge is applied to the fluid, this causes the fluid molecules to repel each other, following the principle that molecules with opposite charges will attract and molecules with like charges will repel. -
Page 6: Electrostatic Spray Control Panel
SECTION ELECTROSTATIC SPRAY CONTROL PANEL SPRAY CONTROL PANEL ® The AutoJet ES250 Electrostatic Spray Control Panel supplies the required voltage to the electrostatic nozzles via a 30,000 VDC (30 kVDC) negative polarity HVPS. At the control panel, the operator can adjust the applied voltage, pump frequency and start or stop the system modes. -
Page 7: Connecting The High Voltage Cable
The reset pushbutton strobes and follows the run sequence. This means that while the system is lubricating, the pushbutton will strobe in sync with the stroke of the piston pump. When the system stops lubricating but the power remains on, the pushbutton returns to a constant illumination. If a fault is detected, the reset pushbutton will cease illumination and the stop pushbutton will begin to illuminate. -
Page 8: Circuit Board (Pcb) And Terminal Block Diagram
4.3 CIRCUIT BOARD (PCB) AND TERMINAL BLOCK DIAGRAMS Figure 4.3-1: PCB diagram PCB TERMINAL BLOCK INFORMATION The following table contains PCB terminal block descriptions. Input power connection 24 VDC, 2.5 amp. (Customer supplied) 24 VDC Source Factory Use Only Jumpers must be installed in slots 4 and 5 Factory Use Only Ground Connection Provides a ground for components powered by block J2... - Page 9 TERMINAL BLOCK J1 Terminal Block J1 is used to provide power to the spray control panel via the connector. Figure 4.3-2: Location and connector for Terminal Block J1. TERMINAL BLOCK J2 AND J5 EXAMPLE DIAGRAM Block J2 provides 24 VDC only and Block J5 is ground only. This provides the option to power components such as proximity sensors or pressure switches.
- Page 10 CONTROLLER DOOR PUSHBUTTON/INDICATOR CONNECTIONS SPRAY CONTROL PANEL DOOR SWITCH AND INDICATOR DIAGRAM—BLOCK J6 Interior Front Panel Switches POWER ON Terminal Block J6 POWER ON STOP STOP RESET Figure 4.3-4: Terminal block J6 RESET HIGH VOLTAGE CONNECTION DIAGRAM—BLOCK J7 CONNECTION REFERENCE* *Connections come landed from factory.
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Page 11: Input Details
4.4 INPUT DETAILS WARNING: Maximum temperature rating 120°F (49°C) ATTENTION: The Electrostatic Spray Control Panel requires a customer supplied 24 VDC, 2.5 A. Inputs 1 thru 10 require 24 VDC and 1.25 mA to energize. Typical Input Connections INPUT CONNECTIONS: J9 TERMINAL BLOCK Terminal Block J9 24 VDC Open switch = OIL LEVEL... - Page 12 INPUT DESCRIPTIONS: J9 TERMINAL BLOCK Not all inputs need to be used. The user should determine which inputs are most important for the application. Odd numbered connections are for +24 VDC power source; even numbered connections are for connection to positive side of the load.
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Page 13: Output Details
4.5 OUTPUT DETAILS Output Connections OUTPUT CONNECTIONS: TERMINAL J10 Terminal Block J9 Sinking Output Wiring Output 10 Wiring +24 VDC 24 VDC Piston Pump Solenoid Sourcing Output Wiring Output 9 Wiring +24 VDC 24 VDC Diaphragm Pump Solenoid Figure 4.5: Output Connections Outputs 1 to 8 are isolated general purpose These outputs contain PTC Thermistors with a trip rating of 750 mA at 20 °C (68 °F). - Page 14 OUTPUT DESCRIPTIONS: TERMINAL J10 Not all outputs need to be used. The user should determine which outputs are most important for the application. Odd numbered connections are for +24 VDC power source; even numbered connections are for connection to positive side of the load.
- Page 15 INPUT BYPASS SWITCHES (DIP SWITCH) Input Bypass Switches allow system operators to toggle Inputs 3-10 on or off. The table below offers a short descrip- tion of each switch, and lists the factory recommended switch setting if appropriate. Dip Switch Name Switch Position On: Constant Lubrication Mode Switch 1 –...
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Page 16: Potentiometers
4.6 POTENTIOMETERS PUMP Adjustment (PUMP ADJ) – Output 10 The PUMP ADJ potentiometer is used to increase or decrease the frequency of Output 10 which affects the pump frequency. The pump frequency is adjustable from 20 – 80 cycles per minute. Rotating the potentiometer dial clockwise will increase the output frequency. - Page 17 If the system is in Prime mode, the following will occur: • Output 9 will be energized (lubrication on) • Output 10 will output a 120 cycle per minute pulse train to rapidly cycle the piston pumps • The Blue LED indicator on the control panel door will strobe in sync with Output 10 •...
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Page 18: Optional Pcb Inputs And Connections
LUBRICATION MODE Terminal Block J9 - INPUT 3 - Connection 5 & 6 Input 3 is the customer lubrication input. The input can be from a normally-open switch, normally-open relay contacts, or from a PLC output. When the contacts are closed (24VDC is supplied to the input), the system will be in Lubrication mode. -
Page 19: Verifying The Spray Control Panel Set Up
When a Pressure Fault is detected, the following will occur: • Output 1 (system healthy) will de-energize • Output 2 (general fault) will energize indicating a General Alarm • Output 5 (nozzle pressure fault) will energize • Outputs 8-10 will de-energize (factory use, lubrication cycle, piston pump) •... -
Page 20: Fluid Reservoir Assembly
SECTION 5 FLUID RESERVOIR ASSEMBLY 5.1 MOUNTING AND POSITIONING FLUID RESERVOIR ASSEMBLY The fluid reservoir assembly includes pumps, an air pressure regulator with a built in particle filter, and the fluid reser- voir tank. The piston pump powers lubricant delivery from the reservoir to the nozzle. The pressure regulator with built in parti- cle filter provides clean, controlled air pressure to the pump for its operation. -
Page 21: Fluid Reservoir Connections
5.2 FLUID RESERVOIR CONNECTIONS FLUID LINES The fluid line originates from the fluid reservoir and connects to the pump. The line then runs out to the electrostatic nozzle through 1/4 in. OD push-to-connect fittings. AIR LINES The air input connects to the air pressure regulator using 1/4 in. NPT. The regulator connects to the pump through 1/4 in. -
Page 22: Lubricant Pump
5.3 LUBRICANT PUMP System fluid delivery is powered by a small piston pump. This type of pump is commonly used in applications when low flow rates are desired for chain lubrication. The system includes an air pressure regulator assembly to power the pump. -
Page 23: Components
5.4 Components FLUID RESERVOIR COMPONENTS The air pressure switch, solenoid cable, and fluid level float switch are all wired back to the Electrostatic Spray Control Panel. • The air pressure regulator (Figure 5.4-1) connects Block J9 and Input 9 • The solenoid cable (Figure 5.4-2) connects Block J10 and Output 10 —The cable includes two black wires and a ground wire. - Page 24 ATTENTION: The operating pressure of the pumps is 0.1 MPa (14.5 psi) – 0.6 MPa (87 psi). An air pressure setting outside of the pump operating pressures may cause flow problems or pump failures. When the desired pressure setting is reached, push the adjustment knob towards the air pressure gauge until it clicks. This will lock the adjustment knob in position.
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Page 25: Particulate Filter
5.6 PARTICULATE FILTER The particulate filter (five micron) is included to prevent moisture and dirt from entering the solenoid valve by way of the compressed air line. Excess moisture will condense inside the attached polycarbonate bowl. The polycarbonate bowl water level can be viewed through the slots of the metal bowl protector. -
Page 26: Electrostatic Chain Oiler Spray Nozzle
SECTION 6 ELECTROSTATIC CHAIN OILER SPRAY NOZZLE 6.1 NOZZLE OVERVIEW ELECTROSTATIC CHAIN OILER SPRAY NOZZLE The Electrostatic Chain Oiler Spray Nozzle delivers the electrostatically charged fluid to the target. Using the spray control panel, operators can adjust the voltage level applied to all nozzles that are connected to that panel. Each nozzle is connected to its own individual piston pump, which allows for some independent adjustment of pump flow rate. -
Page 27: Nozzle Connections
6.2 NOZZLE CONNECTIONS Fluid Line Fluid line tubing must be made from a material that is compatible with the fluid being sprayed. Tubing must be rigid enough to be compatible with the 1/4 in. (6.4 mm) OD push-to-connect fittings that are supplied with the nozzle assembly. -
Page 28: Nozzle Configuration And Adjustment
6.4 NOZZLE CONFIGURATION AND ADJUSTMENT ELECTROSTATIC VOLTAGE The electrostatic nozzle is rated for between 0–30,000 volts. This voltage range allows for variation in fluid viscosities and allows for adjustments to both spray pattern and drop size. WARNING: Do not exceed voltage rating for nozzle assembly. Serious injury or death may occur. Initial Nozzle Configuration Begin with the nozzle tip positioned 1/2 in. -
Page 29: Faults And Troubleshooting
SECTION 7 FAULTS AND TROUBLESHOOTING 7.1 FAULTS AND FAULT CODES The system can generate one fault code at a time. If a second fault condition occurs, it will register after the reset button has been pressed and the first fault has been resolved. The Stop button LED will display a 250 mS ON pulse (button illuminated) followed by a 250 mS OFF pulse (button not illuminated). -
Page 30: Fault Led Status
Fault LED 7.2 FAULT LED STATUS Fault LED Status: Steady Illumination—Stop Fault Cause Solution STOP button has been pressed Press the RESET button on the spray control panel door Wire from STOP button or terminal Repair the connection and press RESET button on the spray control panel block is disconnected door STOP button contact block is faulty... - Page 31 Fault LED status: 6 Pulses—Nozzle 2 Pressure Low Fault Cause Solution Correct the condition that opened the switch then press the Input 7 sensor switch open RESET button on the spray control panel door If the input is not being used, the Input Bypass DIP Switch must Input 7 is not being utilized and Input 7 Bypass DIP be in the “ON”...
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Page 32: General System Troubleshooting
7.3 GENERAL SYSTEM TROUBLESHOOTING If any system or system component malfunctions occur, shut off the system immediately and perform the following steps: • Disconnect and lock out electrical power • Close pneumatic shutoff valves and relieve the pressure • Identify and correct the malfunction before restarting the system •... -
Page 33: Arc Fault Troubleshooting
7.4 ARC FAULT TROUBLESHOOTING CAUTION: Place the ends of the disconnected cables at least six (6) inches away from any grounded surface. Arc Faults Cause Solution Move the nozzles further away from the target and try again. Visible electrical arc at the nozzle after pressing the TEST button Purge the fluid lines to remove any possible air pockets in the nozzle Lower the high voltage output by turning the H.V. -
Page 34: Spare And Replacement Parts
SECTION 8 SPARE AND REPLACEMENT PARTS System configuration specific spare parts are not universal to all ES250 systems. Take note of which pump configuration, nozzle connection type, and nozzle tip is used with your system prior to ordering any spare parts. Standard replacement parts are compatible with all ES250 configurations. - Page 35 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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