Spraying Systems AutoJet 2850+ Owner'S Manual Download Page 5

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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.

RUNNING THE SYSTEM:



Plug in GFCI.



Turn on GFCI by depressing green button on GFCI.



Press amber POWER ON button on front panel. Input all
settings PRIOR to pressing channel 1 run for the first time.

Inspections, Cleaning, Replacement Parts:

•

Check condition of power plug regularly.

•

Control panel can be cleaned with non

aggressive cleaning

agents, e.g. isopropyl alcohol

Maintenance/repair other than described is intended to be performed by skilled personnel.

SPECIFICATIONS:

•

16x PG7 cable gland

•

Nozzles, EMC cable glands and shielded cables ordered separately

•

Technical Documentation Set

•

Leave the system (parts) in the original packaging for transportation and storage.

•

Until assembly, store in a dry place at a room temperature between 32° F and 122° F (0 and 50°C).

•

Do not drop any of the parts.

•

Mount the panel so that the power buttons and HMI are easily accessible/visible.

Summary of Contents for AutoJet 2850+

Page 1: ...AutoJet 2850 Spray Control Panel OWNER S MANUAL ML002850PLUS spray com ...

Page 2: ...pray Timing 19 7 Configuration Screens 23 7 1 System Configuration 23 7 2 CH1 Line Speed Setup 23 7 3 CH1 Liquid Pressure Setup 24 7 4 CH1 Atomizing Air Pressure Setup 26 7 5 CH1 Flow Meter Setup 27 7 6 Remote Setpoint Setup 29 7 7 Header Info 30 8 Alarm Settings 31 8 1 Overview 31 8 2 Liquid Pressure Alarm Setup 31 8 3 Atomizing Air Pressure Alarm Screen 32 8 4 Flow Alarm Setup 32 8 5 Liquid Leve...

Page 3: ...th and or damage the system CAUTION Product process or environment can be damaged or be in danger if the instructions are not followed correctly ATTENTION Supplementary information for the user that draws attention to possible problems SECTION 2 SAFETY 2 1 GENERAL SAFETY INFORMATION READ AND FOLLOW INSTRUCTIONS All safety related and operating instructions should be read before the system is opera...

Page 4: ...re can penetrate skin and cause severe injury ATTENTION Always remember to carefully read the chemical manufacturer s labels follow SDS and all directions 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 conta...

Page 5: ...g channel 1 run for the first time Inspections Cleaning Replacement Parts Check condition of power plug regularly Control panel can be cleaned with non aggressive cleaning agents e g isopropyl alcohol Maintenance repair other than described is intended to be performed by skilled personnel SPECIFICATIONS 16x PG7 cable gland Nozzles EMC cable glands and shielded cables ordered separately Technical D...

Page 6: ...buttons are not used under normal operating conditions Item Description Function Power On Electrical power enable power indicator Power Off Electrical power disable Stops system Manual Spray Trigger Ch 1 Ch 2 Used to manually trigger spray for the respective channel Manual Spray Trigger Reset Ch 1 Ch 2 Used to manually reset spray trigger for respective channel Alarm Reset Resets Alarm Alarm Horn ...

Page 7: ...power supply 2008 Module Standard Model 2008 PWM driver module 2nd channel optional 2008 Module Optional Model 2008 PWM driver module for optional 2nd channel PLC Logic Control Air Manifold Optional Air distribution manifold Included with other air control options I P Optional Proportional current to pressure regulator 1 or 2 in panel regulator options available Solenoid Valve Optional Optional 3 ...

Page 8: ... Calibrate as required See individual control component manuals for calibration procedures Description Username Password Operator OPER O Engineer ENG E PLC Tag Name Variable Type Address 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 C...

Page 9: ...figure analog inputs and outputs or manual setpoints related to sensors and actuators Navigates to Header Info screen Use to enter Spray Width Reference Flow Ref erence Pressure Enable Disable Zone Control and Configure Zones Navigates to the alarm page Access to alarm history view active alarms and change alarm settings per channel Note Turns red while alarms are active as shown here Navigates to...

Page 10: ...guns is displayed here The Duty Cycle can be changed here while in Duty Cycle regulation mode Theoretical Flow Rate read only The maximum flow rate possible based on the current liquid pressure reference flow and reference pressure of the tip Liquid Pressure read only The liquid pressure is displayed from a pressure transmitter The controller uses feedback from this transmitter to hold the pressur...

Page 11: ...ow Air Act Uses I P to regulate flow Used with air actuated nozzles Constant Flow PWM Based on the liquid pressure reference flow and pressure the con troller will calculate the correct duty cycle to maintain the flow rate setpoint Used with PWM nozzles only Application Rate PWM This sets the system to apply a constant application rate of liquid per unit of surface area of substrate on a moving co...

Page 12: ...sure based on nozzle selection to maintain the amount of fluid distributed per surface area on a moving conveyor The rate of liquid will vary as the line speed varies but the add on rate to the substrate will remain fixed Only used based on regulation mode chose Shot Weight SP editable Enter the desired weight of each shot or weight sprayed on each product Manual DC Entry editable Manually Enter D...

Page 13: ... default number of max cy cles per minute allowed by the spray gun only if necessary This is used to calculate the nozzle signal frequency Min Cycle editable This is auto populated based on nozzle selection Edit the default minimum number of cycles per minute the system should try to maintain only if necessary This is used to calculate the nozzle signal frequency Anticipator Time editable Enter th...

Page 14: ...next time the nozzle turns on is called the period in this case 1 10th of a second Within a single period the nozzle is switched on then off The time that the nozzle is on divided by the total time of the period gives a percentage which is called the duty cycle For example if the period is 0 10 seconds and the nozzle is on for half of that time then the duty cycle is 50 For the same period if the ...

Page 15: ...settings allows for the editing of the minimum and maximum cycles per minute as well as the spray thickness which is the depth of the spray pattern Maximum cycles speed is 15 000 cycles min minimum range is 0 60 cycles min Maximum cycle speed Maximum speed that the nozzle should switch at for this application This entry will be limited by the type of nozzle selected Minimum cycle speed Minimum cyc...

Page 16: ...ith repeat Variable spray time no repeat Variable spray time with repeat Timing modes are selected by going to the HMI settings page and selecting the Timing button The system will spray for a predetermined time depending on the timing mode selected The spray controller allows for accurate time based control over the spray nozzle based on an external trigger signal SPRAY PERIOD The spray period is...

Page 17: ... WITHOUT SPRAY OVERLAP Occurs if the system receives multiple start events rising edge of trigger signal before a spray cycle is finished If the time delay between two successive start events or trigger pulses is higher than the spray time then there is no overlap SPECIAL CASE MULTIPLE TRIGGERS WITH SPRAY OVERLAP Occurs if the system receives multiple start events rising edge of trigger signal bef...

Page 18: ...emain on Note This can happen in both fixed and Variable spray times Sum of Anticipator and Follower Time is Higher Than Start Delay Time If anticipator time follower time off period then the air will be kept on during the complete repeat cycle Repeat Spray Repeat spray air overlap PARAMETER VALUE Start Delay In seconds s or meters m requires speed sensor Off Period In seconds s or meters m set va...

Page 19: ...sor and the position of the spray nozzle The spray distance or time will now always be exactly the same as the object length or time INCREASED SPRAY LENGTH Decrease Start delay The spray is started before the object has reached the spray nozzle Increase Stop delay The spray continues after the object has passed the spray nozzle Variable spray time increased spray period Variable Spray Time PARAMET...

Page 20: ...DURING SPRAY If the system receives multiple start events before the spray cycle is finished they will be added to a queue and executed according to the given delay times OVERLAPPING SPRAY EVENTS If spray events overlap the overlapping event will be ignored and the system will continue to spray to ensure the objects are sprayed correctly This situation may occur when the following is true stop del...

Page 21: ...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 The start and stop delays are typically the distance between the object sensor and the spray nozzle The spray period is limited in time to the configured spray period In this timing mode the repeat functionality works in time units Variable spray period ...

Page 22: ... input Variable spray length with repeat diagram PARAMETER VALUE Start Delay In seconds s or meters m requires speed sensor Stop Delay In seconds s or meters m requires speed sensor Repeat Off Period In seconds s or meters m requires speed sensor set value greater than 0 Repeat On Period In seconds s or meters m requires speed sensor set value greater than 0 Spray Period Set value equal to 0 Antic...

Page 23: ...e feedback Installed There is an encoder installed and will be used when utilizing relevant feedback loops Manual Allows for a user to enter a line speed that can be used for feedback loops instead of the actual line speed Copy From Ln Spd 1 channel 2 only Uses the line speed input from channel 1 for channel 2 Speed Signal Input selection Selects what kind of signal the encoder is sending HI SPD C...

Page 24: ...for a user to enter a liquid pressure that can be used for feedback loops instead of the actual pressure Copy From LPT 1 channel 2 only Uses the liquid pressure input from channel 1 for chan nel 2 Span editable Set the span of the liquid pressure sensor based on a 4 20mA scale with 4mA being 0 by default and 20mA will be the span you enter in this field Filter Constant Smooths out input reading be...

Page 25: ...s PV read only Process Value Display of the current liquid pressure Liq Press CF editable The liquid pressure correction factor is determined by running the PID in closed loop It can be manually adjusted while in open loop Kp editable Enter the desired Kp value for PID control Ki editable Enter the desired Ki value for PID control PID DLY editable Allows the user to enter a time delay between the ...

Page 26: ...n a 4 20mA scale with 4mA being 0 by default and 20mA will be the span you enter in this field Ch 1 Atom Air I P Output toggle Turns on or off the atomizing air pressure signal output Span editable Sets the 20 mA output of the atomizing air pressure signal with 4 mA being 0 PSI Ch1 Atomizing Air Pressure PID Takes the user to the channel 1 atomizing air pressure PID screen Item Description Atomizi...

Page 27: ...f the actual pressure Span editable Set the span of the atomizing air pressure sensor based on a 4 20mA scale with 4mA being 0 by default and 20mA will be the span you enter in this field Shot Volume selection Off Shot volume is off and hidden on the operating screen On Shot volume is on and displayed on the operating screen Shot Volume Alarm on the alarms screen is used to setup parameters Flow I...

Page 28: ...ined by running the PID in closed loop It can be manually adjusted while in open loop Kp editable Proportional value in the PID loop Ki editable Integral value in the PID loop Kd editable Derivative value in the PID loop Duty Cycle read only Displays current duty cycle PID DLY mS editable Sets the PID delay or time until the PID begins working to allow for values to ramp up Graph Scale editable Ch...

Page 29: ...tion factor is determined by running the PID in closed loop It can be manually adjusted while in open loop Kp editable Proportional value in the PID loop Ki editable Integral value in the PID loop Kd editable Derivative value in the PID loop Duty Cycle read only Displays current duty cycle LN SPD FT MIN read only Displays current Line Speed PID DLY mS editable Sets the PID delay or time until the ...

Page 30: ...o remote input selected system will use local setpoints Analog Input Uses the analog input to determine the flow rate setpoint Ethernet Uses ethernet input to determine the flow rate setpoint Remote AppRate mL SQ FT selection Select where the remote setpoint for application rate is coming from No Remote Input No remote input selected system will use local setpoints Analog Input Uses the analog inp...

Page 31: ... Note Channel 1 and Channel 2 screens contain identical fields and options except where noted 8 2 LIQUID PRESSURE ALARM SETUP SECTION 8 ALARM SETTINGS Item Description Ch1 Liq Press Alarm toggle Enables or disables the liquid pressure alarm Min Pressure editable Sets the minimum pressure allowable before alarming Max Pressure editable Sets the maximum pressure allowable before alarming Tolerance T...

Page 32: ...rm toggle Enables or disables the Flow alarm Low Percentage editable Sets the minimum percentage of flow rate allowable before alarming This percentage is based off the setpoint in the active recipe High Percentage editable Sets the maximum percentage of flow rate allowable before alarming This percentage is based off the setpoint in the active recipe Tolerance Time editable Sets the maximum allow...

Page 33: ... Weight alarm Low Percentage editable Sets the minimum percentage under the shot volume allowable This percentage is based off the setpoint in the active recipe High Percentage editable Sets the maximum percentage over the shot volume allowable This percentage is based off the setpoint in the active recipe Alarm If _ Bad editable Enter the number of allowable shots outside the setpoint and error p...

Page 34: ...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 This percentage is based off the setpoint in the active recipe Tolerance Time editable Sets the maximum allowable time outside the max or min application rate before alarmin...

Page 35: ...ded IO or monitors the IO of the PLC and to some extent the 2008 modules 9 2 ANALOG IO MONITOR The analog IO screen displays the current analog values for the controller and can be used for troubleshooting purposes The dis played value is the number of counts re ceived Divide by 1000 and that will corre spond to the mA received 9 3 PLUGIN RELAY OUTPUT Plugin relay output page displays the status o...

Page 36: ...tity disallow striping and spray to little avoid striping by spraying at 100 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 Clean Duty Cycle editable Enter the duty cycle the nozzles will use during the clean cy...

Page 37: ...on in the top right of that screen Resetting the screen will not affect the PLC or HMI programs in any way The screen map can also be navigated to from here and can be useful to access a desired page 10 2 SCREEN MAP The screen map allows the user to jump to any screen The change password button allows the user to change its pass word The user must be logged in and can only change passwords of the ...

Page 38: ...ial Fixes CH1 CH2 LIQUID PRESSURE ALARM The liquid pressure on channel 1 channel2 has deviat ed outside the user set tolerance range for the user specified tolerance time Check pump is on and liquid present Check manual valve orientation if present If desired ensure that the Liquid Pressure PID is in closed loop Navigate to Sensor configuration screen and check the sensor is configured correctly C...

Page 39: ...ult System integrity flowmeter 1 8 when compared to theoretical flow is not reading an expected value Navigate to the System Integrity screen and look for discrepancies between the flowmeter readings Ensure that these readings are reflected correctly on the physical flowme ters themselves if accessible Clean the tip s of nozzle s attached to the alarming meter s Check that alarm tolerance time and...

Page 40: ... 1 year on non wear parts from ship date Wear items are covered for manufacturing defect only for a period of one 1 year Wear items include but may not be limited to the liquid pump and liquid regulator Seller warrants that its products will conform to and perform in accordance with the products specifications Seller warrants that the products do not infringe upon any copyright patent or trademark...

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