Spraying Systems AutoJet ES250 Bedienungsanleitung

AutoJet® ES250

Electrostatic Chain

Oiler System

ML00ES250F

spray.com

OWNER’S MANUAL

 Preface ········································································································································ 3
1 Important ········································································································································ 3
2  How To Use This Manual················································································································ 3
 Safety ·········································································································································· 3
1  General Safety Informaon············································································································ 3
2 Unpacking the System····················································································································· 4
 ES250 Overview ··························································································································· 5
1  Electrostacs Spraying Overview··································································································· 5
2  System Components and Installaon Requirements····································································· 5
 Electrostac Spray Control Panel·································································································· 6
1  Mounng the Panel and Door Diagram ························································································· 6
2  Connecng the High Voltage Cable································································································ 7
3  Circuit Board (PCB) and Terminal Block Diagram··········································································· 8
4  Input Details ································································································································· 11 
5  Output Details ······························································································································ 13 
6  Potenometers ···························································································································· 16 
7  System Modes······························································································································ 16 
8  Oponal PCB Inputs and Connecons ························································································· 18 
9  Verifying the Spray Control Panel Set Up ···················································································· 19 
 Fluid Reservoir Assembly ··········································································································· 20 
1  Mounng and Posioning············································································································ 20 
2  Fluid Reservoir Connecons········································································································· 21 
3  Lubricant Pump ···························································································································· 22 
4  Components ································································································································· 23 
5  Air Pressure Regulator·················································································································· 23 
6  Parculate Filter··························································································································· 25 
7  Verifying the Fluid Reservoir Assembly Set Up············································································ 25 
 Electrostac Chain Oiler Spray Nozzle························································································· 26 
1  Nozzle Overview··························································································································· 26 
2  Nozzle Connecons······················································································································ 27 
3  Nozzle Disassembly Procedure ···································································································· 27 
4  Nozzle Conguraon and Adjustment························································································· 28 
 Faults and Troubleshoong········································································································ 29 
1  Faults and Fault Codes ················································································································· 29 
2  Fault LED Status···························································································································· 30 
3  General System Troubleshoong································································································· 32 
4  Arc Fault Troubleshoong············································································································ 33 
 Spare and Replacement Parts····································································································· 34 
 
TABLE OF CONTENTS 

1.1 IMPORTANT

The AutoJet® ES250 Electrostac Chain Oiler System and its components are produced, tested, and checked at the

factory. The system can be dangerous if used incorrectly. Read this manual carefully and pay special aenon to any

safety instrucons.

Operators must always follow the general safety instrucons in the working area and aim to prevent accidents.

The manufacturer reserves the right to make changes in standard construcon without prior nocaon.

Images and diagrams in this manual may not be exact representaons of your system conguraon.

1.2 HOW TO USE THIS MANUAL

This manual is intended to be a source of informaon for the operators and technicians who may be installing, inter-

acng with or servicing/maintaining Spraying Systems Co.® systems and components.

This manual contains important safety warnings, installaon instrucons, operang instrucons, troubleshoong

and maintenance informaon.

ICONS

WARNING: The user can be seriously injured, damage their health, and/or damage the system.

CAUTION: Product, process, or environment can be damaged or be in danger if the instrucons are

not followed correctly.

ATTENTION: Supplementary informaon for the user that draws aenon to possible problems.

2.1 GENERAL SAFETY INFORMATION

READ AND FOLLOW INSTRUCTIONS

All safety-related and operang instrucons should be read before the system is operated. Follow all operang

instrucons.

SERVICING

Do not aempt to service this system unless you have been trained or authorized to conduct repairs. Only authorized

and qualied service personnel should aempt to service this system. Service by unauthorized personnel may void any

and all warranes.

WARNING: Before performing any maintenance, make sure electrical power is o and any air/liquid

pressure is bled from the system.

REPLACEMENT PARTS

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 operaon, electrical and pneumac safety. The use of any unauthorized replacement parts will void any

warranes.

UNINTENDED USE

Use of Spraying Systems Co.® equipment in ways other than those described in the documentaon supplied with the

equipment may result in injury to persons or damage to property. Examples of unintended use of equipment:

SECTION 2

SAFETY

SECTION 1

PREFACE

• Using incompable materials or damaged parts

• Making unauthorized modicaons or using unapproved auxiliary equipment

• Removing or bypassing safety guards or interlocks

• Operang equipment in excess of maximum rangs

REGULATIONS AND APPROVALS

Make sure all equipment is rated and approved for the environment in which it is used. Any approvals obtained for

Spraying Systems Co. equipment will be voided if instrucons for installaon, operaon, and service are not followed.

All phases of equipment installaon 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 potenally

hazardous environments and chemicals. This safety equipment includes, but is not limited to, the following:

• Protecve hat, chemical-resistant safety gloves, and apron

• Safety glasses/face shield, long sleeve shirt and long pants

Users of this product should never place themselves in the path of the spray. Users should consult and follow the

recommendaons of the Safety Data Sheet (SDS) of any chemical or uid sprayed using this system.

PRESSURIZED SYSTEMS

It is important to recognize proper safety precauons when using a pressurized spray system. When dealing with

pressure applicaons, the system pressure should never exceed the lowest rated component. Always know your

system, all component capabilies, maximum pressures and ow rates.

WARNING: Fluids under pressure can penetrate skin and cause severe injury.

ATTENTION: Always remember to carefully read the chemical manufacturer's labels, follow SDS and

all direcons.

WARNING OF SHOCK HAZARD

To reduce the risk of electric shock, do not open the cover on electrical control panel. For service contact

Spraying Systems Co.® at 1-866-321-2250.

WARNING: Plug panels into A GFCI outlet.

WARNING: To prevent injury, avoid contact with potenally hot parts. Components can cause severe

burns. Do not aim the spray at any person or part of the body. Do not place any part of your body

into the spray paern.

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 eects. Because of the large number of chemicals that could be used and their dierent

chemical reacons, the buyer and user of this equipment should determine compability of the materials used and any

of the potential hazards involved.

2.2 UNPACKING THE SYSTEM

The system components come carefully packaged to protect them from damage. Use cauon when opening the crate.

The crate will contain all parts needed to install the unit. Parts of the unit may be wrapped in bubble wrap. Remove all

of the packaging material wrapping the system. Once unpacked and removed the from the crate, the system is ready

for installaon and connecon.

CAUTION: The packaging may contain exposed cables, hoses, and other components. Always

exercise cauon when opening boxes to avoid accidental damage or slicing of various components.

3.1 ELECTROSTATICS SPRAYING OVERVIEW

In electrostac spraying, a negave charge is introduced into a uid in the nozzle body through a central charging elec-

trode, which causes the uid to acquire a negave charge. When this negave charge is applied to the uid, this causes

the uid molecules to repel each other, following the principle that molecules with opposite charges will aract and

molecules with like charges will repel. Electrostac spraying relies on the repulsion of these like-charged small uid

droplets.

Aer leaving the nozzle orice, the uid molecules connue to repel each other as they travel, causing the already

small droplets to break up into even smaller droplets. This process will connue unl the repulsive force between the

molecules is no longer strong enough to break the surface tension and split the droplet again.

These ny and uniformly sized droplets retain their negave charges and will be aracted to any neutral, grounded

target nearby with an aracve force stronger than gravity. Electrostac forces pull the liquid molecules towards this

target, thinly and evenly coang the target surface and providing a very high uid transfer eciency

Some benets of electrostac spraying include:

• Low ow rates that allow for less uid usage

• Reduced product and workspace contaminaon due to overspray

• Shorter workspace cleanup mes

• Longer intervals between system maintenance

• More uniform target coangs, typically achieving over 90% transfer eciency

3.2 SYSTEM COMPONENTS AND INSTALLATION REQUIREMENTS

This electrostac system includes the following main components:

• AutoJet® ES250 Electrostac Spray Control Panel

• Fluid Reservoir Assembly

• Electrostac Chain Oiler Spray Nozzle

CUSTOMER REQUIREMENTS FOR INSTALLATION

• Mounng locaons for all components that meet any and all naonal or local safety standards

• 40 psi (minimum) shop air connecon

• 24 VDC power supply to provide power to the control panel’s circuit board, the solenoid valve connecon, and the

high voltage power supply (HVPS) —2.5 amp minimum

REQUIRED TOOLS FOR INSTALLATION

• 15 mm open ended wrench and 27 mm open ended wrench.

• Sloed screwdriver 3/8” (9.5 mm) or larger for accessing the panel)

• #2 Phillips head screwdriver (for removing the high voltage terminal block enclosure cover)

• #2 Square bit screwdriver or 3/8” (9.5 mm) sloed screwdriver (for ghtening high voltage terminals)

• 1/8” (0.125 mm) sloed screwdriver (for terminals)

• Wire strippers

SECTION 3

ES250 OVERVIEW

SECTION 4

ELECTROSTATIC SPRAY CONTROL PANEL

SPRAY CONTROL PANEL

The AutoJet® ES250 Electrostac Spray Control Panel supplies the required voltage to the electrostac nozzles via a

30,000 VDC (30 kVDC) negave polarity HVPS. At the control panel, the operator can adjust the applied voltage, pump

frequency and start or stop the system modes.

GASKET

The control panel has a gasket installed which creates a seal between the door and the body of the unit. Exercise

cauon when opening the unit door as to not damage the gasket. Debris inside the control panel may cause damage to

the system.

4.1 MOUNTING THE PANEL AND DOOR DIAGRAM

MOUNTING

When selecng a control panel mounng locaon, consider the high voltage cable roung required and your

purchased cable length in relaon to the nozzle mounng locaon. Make sure the control panel is mounted within an

acceptable distance to the nozzle, it is easily accessible to system operators, and the grounding lug is connected to a

grounded GFCI outlet (Figure 4.1).

If mounng the panel to the wall, in a locaon that is close to your nozzles install wall anchors that are designed to

support at least 25 lbs. (11.34 kg) according to the anchor manufacturer’s specicaons. The mounng holes are on

6” (152 mm) centers and are made for 1/4” (6 mm) screws with 3/8” (10 mm) diameter screw heads (Figure 4.1-1).

Figure 4.1-2: Labeled control panel door diagram

Figure 4.1-1: Dimensions and mounng hole paern

SPRAY CONTROL PANEL DOOR LABELED DIAGRAM

The control panel door uses illuminang pushbuons to relay system informaon. The POWER switch will illuminate

when system power is on. The RESET and STOP pushbuons will illuminate related to system operaon and fault

status (Figure 4.1-2).

Reset Pushbuon: Illuminates when no

fault condion is detected.

Push to reset aer correcng a system

fault

Stop Pushbuon:

When pressed, OUTPUT 2

will turn on and pushbuon

will illuminate

Power Switch:

Will illuminate

when the system

is powered on

10.72” (272 mm)

6” (152 mm)

R. 0.13” (3 mm)

Figure 4.1: Grounding lug

4.2 CONNECTING THE HIGH VOLTAGE CABLE

WARNING: Before installaon, ensure that the spray control panel is turned o and power is

disconnected.

CAUTION: Make sure high voltage cables are properly grounded. Failure to ground may cause a

power surge on the system and damage the control board.

SUGGESTED TOOLS

• A properly sized adjustable wrench (for cord grips)

• Sloed screwdriver (3/8” or larger for accessing the panel)

• #2 Phillips head screwdriver (for removing the high voltage terminal block enclosure cover)

• 1/8” Sloed screwdriver (for terminals)

• Wire strippers

Figure 4.2: Connecng the high voltage cables to the spray control panel.

CABLE CONNECTION PROCESS

• Remove high voltage block cover and silicone gasket

• Slide cables through the grommets in the boom of the control box

• Connect cables to the high voltage terminal block bus bar

• Push cables into clamps on the grounding bracket, conrm grounding mesh is in clip

• Aach wire e around cable and clip

• Make sure grounding wire is connected from grounding bracket to grounding lug and reinstall cover and

silicone gasket

The reset pushbuon strobes and follows the run sequence. This means that while the system is lubricang, the

pushbuon will strobe in sync with the stroke of the piston pump. When the system stops lubricang but the power

remains on, the pushbuon returns to a constant illuminaon.

If a fault is detected, the reset pushbuon will cease illuminaon and the stop pushbuon will begin to illuminate. The

stop pushbuon will pulse in accordance with the number of pulses that have been set for the detected system fault.

See Secon 7.1 Faults and Fault Codes for more informaon.

Figure 4.3-1: PCB diagram

PCB TERMINAL BLOCK INFORMATION

The following table contains PCB terminal block descripons.

4.3 CIRCUIT BOARD (PCB) AND TERMINAL BLOCK DIAGRAMS

J1 Input power connecon

24 VDC, 2.5 amp. (Customer supplied)

J2 24 VDC Source

J3 Factory Use Only

Jumpers must be installed in slots 4 and 5

J4 Factory Use Only

J5 Ground Connecon

Provides a ground for components powered by block J2

J6 Panel Pushbuons & Indicators

See Page 17 for diagram

J7 High Voltage Power Supply

See Page 17 for diagram

J8 Factory Use Only

Trigger Input

J9 Input Connecons

See Page 18 for diagram

J10 Output Connecons

See Page 20 for diagram

TERMINAL BLOCK J2 AND J5 EXAMPLE DIAGRAM

Block J2 provides 24 VDC only and Block J5 is ground only.

This provides the opon to power components such as proximity sensors or pressure switches. If your system

conguraon does not require or necessitate the use of external components, Blocks J2 and J5 will likely go unused.

Figure 4.3-3: Example diagram for connecng external pressure transducers

(or any other components) to the system

TERMINAL BLOCK J1

Terminal Block J1 is used to provide power to the spray control panel via the connector.

Figure 4.3-2: Locaon and connector for Terminal Block J1.

SPRAY CONTROL PANEL DOOR SWITCH AND INDICATOR DIAGRAM—BLOCK J6

HIGH VOLTAGE CONNECTION DIAGRAM—BLOCK J7 CONNECTION REFERENCE*

*Connecons come landed from factory.

Figure 4.3-4: Terminal block J6

CONTROLLER DOOR PUSHBUTTON/INDICATOR CONNECTIONS

Terminal Block J6

3 4

X1 X2

1 2

X1 X2

RESET

STOP

POWER ON

3 4

910

11 12

Interior Front

Panel Switches

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