SAS SAS 1E User manual

SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
SAS 1E/2E - Electrostatic Probe Unit
INSTRUCTION MANUAL
Unit 3 Hawksworth, Didcot, OX11 7HR, England, UK
Tel: [phone] Fax: [phone]
[e-mail] www.spiceapplications.com

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
INDEX
DESCRIPTION OF INFORMATION PAGE NUMBERS
WARNINGS OVERVIEW………………………………………………………. 2
EC DECLARATION OF CONFORMITY FOR MACHINERY………………. 3
ELECTROSTATIC INTRODUCTION…………………………………………. 4-5
PRODUCT INTRODUCTION…………………………………………………... 6
INSTALLATION…………………………………………………………………. 7-13
OPERATING PRINCIPLE……………………………………………………… 14-15
START UP…………………………………………………………………….…. 16
STATIC TEST …………………………………………………………………… 17
CLEANING………………………………………………………………………. 18
SERVICING……………………………………………………………………… 19-20
TROUBLESHOOTING…………………………………………………………. 21
SPARE PARTS…………………………………………………………………. 22-25
DIMENSIONS…………………………………………………………………… 26
TECHNICAL SPECIFICATIONS……………………………………………… 27
WARRANTY……………………………………………………………………. 28
To obtain the best performance and reliability from this equipment it is
strongly recommended to read the instruction manual thoroughly
before attempting to use the equipment.

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
WARNINGS OVERVIEW
All controls within the Control Box have been adjusted for optimum performance and
safety during manufacturing.
The Electrostatic Generating heads and control box is sealed for IP 65.
Re-adjustments, alterations or substitutions of any component may result in a
hazardous operating condition a failure and possible damage to the equipment as well
as overriding the built-in safety features.
Any unauthorised modification will invalidate the warranty and could endanger the work
force.
Under no circumstances are any alterations allowed to the electrostatic
equipment without specific written instructions and consent from Spice
Application Systems Ltd.
SAFETY GUIDELINES
The person in charge of the manufacturing work area should ensure that
personnel are properly trained in the use of this equipment. The safety rules
which follow should be fully understood and applied at all times.
Never point the spray unit at any person or animal.
Spraying certain products can be dangerous, depending on what is being
sprayed so full protection for operators in the form of instructions supplied with
that product must be adhered to at all times.
The normal safety rules and precautions for atomisation must be observed.
For more information, consult the local safety rules. In addition, the following
precautions must be observed.
WARNING! Failure to observe the safety precautions contained within this manual
could result in operational difficulties of the equipment and potential to create
unsafe conditions.
ALL personnel who are associated with the coating operation should
read and fully understand this manual. It is especially important that
the operators and maintenance team of the electrostatic equipment
and their supervisory personnel understand the requirements for safe
and proper usage of the electrostatic process.

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
EC DECLARATION OF
CONFORMITY FOR MACHINERY
The manufacturer: Spice Application Systems Ltd
Unit 3, Hawksworth
Southmead Industrial Estate,
Didcot
Oxfordshire
OX11 7HR, England, UK
Tel: [phone]
Fax: [phone]
Herewith declares that “the Electrostatic Food Spray Unit” is in conformity with the provisions
of:
•EU Directive 2014/34/EU –certified as Category 3D 40⁰C and manufactured in line with
Internal Control of Production as outlined in the Directive
•BS EN ISO 12100:1 –Safety of Machinery
•BS EN ISO 12100:2 –Safety of Machinery
•BS EN 60079:0 and BS EN 60079:11 –Equipment for Use in Potentially Explosive
Atmospheres
•EN 50177 –Stationary electrostatic spraying equipment for flammable coating powder
•EN 60204 IP –Type protection: contact, foreign bodies and water protection for electrical
equipment
•EC Machinery Directive 2006/42/EC
•EC Low Voltage Directive 2006/95/EC
•EC Directive of Electromagnetic Compatibility 2014/30/EU
•BS EN 61000-6-3:2001 –Electromagnetic Compatibility
•BS EN 61000-6-1:2001 –Electromagnetic Compatibility
•BS EN 50050-2:2013 –Electrostatic hand-held spraying equipment. Safety requirements.
Hand-held spraying equipment for ignitable coating powder
•Plastic Blue Acetal Copolymer EU Directive 2002/72/EC/FDA Directive 21CFR
•EC No.1935/2004
All as amended, and with national implementing legislation.
Established in Oxford on 1st October 1999.
Peter King
Managing Director

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
ELECTROSTATIC INTRODUCTION
What is Electrostatics
Electrostatics is an environmentally responsible way to applycoating materials, significantly
increasing the qualityof the finished product, while substantially decreasing powder/oil costs
through more effective use of materials.
How does it work?
The aim is to eliminate wasteful over spray and put as much coating material on the targetas
possible. This is achieved by negatively charging atomized powder/oil particles so that they
are attracted to the grounded work piece, opposites attract.
A charging electrode is located at the tip of the electrostatic generator head or atomizer. The
powder/oilisatomizedasitmovespasttheelectrode,itsparticlesbecomeionized-negatively
charged. An electrostatic field is created between the charging electrode and the grounded
work piece, the spray is concentrated within it.
The product to be coated (chips, tablets, etc.) is Grounded from contact within the rotating
drum/wire belt flat chamber. When the coating material is released, it is attracted to the
Grounded product. Due to the electrostatic attraction, coating material that would normally
be lost ends up on the back and sides of the target product to produce a “wrap-around”
effect.

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
ELECTROSTATIC INTRODUCTION
When to use electrostatics!
When you want to achieve maximum transfer efficiency and minimize coating waste and
dusting/misting emissions, while achieving maximum application wrap around effect, high
production and high flow rates.
The advantages!
Up to 98% coating of all products, with greatly improved coating over traditional
methods, less powder usage, cut down of dusting, cleaner working area and cleaner
drum, all resulting in less line contamination.
Increased transferefficiency and reduced over spray, which results in significant cost savings
andreduceddusting/mistingemissions.Webuild our systemwithsafetyinmind,withflexible,
lightweight low voltage cable going to the generating spray head.
Typical Electrostatic Applications
•Pharmaceuticals: coating tablets granule formation
•Horticulture: powder onto seeds
•Agriculture: powder/liquids on potato or cattle feed
•Meat: fresh poultry and processed meats-powder & liquid flavouring
•Fish: oils & powder
•Breakfast Cereals: vitamins & flavouring in powder/liquid form
•Snacks, crisps, nuts, extruded and pasta pellets: powder & liquid spices
•Confectionery: powder onto mints, chewing gum, etc.
•Pet food: powder & liquid enhancers onto kibbles, biscuits & chew bars
•Dairy: starch onto cheese
•Bakery: oil & powder coating onto cakes, burger buns, etc.

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
PRODUCT INTRODUCTION
SAS Electrostatic Probe Model Type: SAS 1E & 2E
This model is designed to create an electrostatic charge on particles which can cause
misting or dusting in the environment.
The SAS Electrostatic Probe unit uses the principal of applying an electrostatic charge
to the airborne before escaping the coating drum. The particles once charged become
negatively charged and are attracted to the nearest grounded object, this typically being
the internal surface of the metal coating drum and the product being coated.
Fig 1
SAS 1E –Electrostatic Probe Unit overview
Pos.
Description
Assembly
Number
Manual Reference
A
Generator Head - Powder
GH 200-161
See page 23 - Fig 10
B
Support bars for Generator Head
GH 200-324
See page 25 - Fig 12
C
Electrostatic Controller
CU 200-124
See page 22 - Fig 9
D
Frame Mounting Bars
GH 200-320
See page 25 - Fig 13
Note ! An SAS 2E Assembly contains one common Electrostatic controller
(see Page 10, Fig 3)
A
B
C
D

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
INSTALLATION
1. The Electrostatic control unit must be located outside the flavouring drum in a Non-
Hazardous area at a location which allows the operators to observe the material
atomisation in front of the tumbling product.
2. To obtain the maximum electrostatic efficiency the electrode needle on the
electrostatic generating head should be positioned towards the centre of the drum in
facing the tumbling product and powder cloud. (see page 14 - Fig 7)
3. The appropriate distance between the generating head and the product to be coated
should be between 20 to 45 cm (8" to 18")
4. Be sure that the distance between the electrode needle on the generating head and
any surrounding metal objects (including any application equipment and the Drum)
is at least 15cm (6”) or greater.
5. Never use damaged hoses, cables or connections.
6. All compressed air connections must be fitted with a local isolator and pressure
regulator, plus fitted with a suitable Filter to ensure a Clean and Dry air supply to the
SAS equipment.
7. Remove all unnecessary metal components and materials from the application
area.
8. Keep the application area clean.
9. The Electrical mains supply must be fitted with an earth wired to the factory mains
earthing system.
10.If the application requires the remote trigger to facilitate the unit to switch on and off
with an existing production line, please refer to page 12 –Fig 6 on the manual.
If not using, make sure the dust caps are fitted and locked into place on the
underside of the SAS Controller. (see page 12 - Fig 5)
11.Ensure all Earthing cables are connected and all other equipment in the application
area is Grounded, including all mobile frames, within 3m (10ft) of the application
area.

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
INSTALLATION
12. The drum must be earthed in 2 places with the earthing contacts rubbing against
the wall of the drum. The outgoing and incoming vibratory conveyors to and from
the drum must always be earthed and all metal within 3mtrs of the drum.
13.All ground connections must be regularly checked and confirmed using a megohm
meter for a resistance of 1 megohm or less from the structure to a positive ground.
(i.e. floor bolt or building steelwork)
14.Any floor coating in the application area must be electrically conductive and
grounded. Do not attempt to by-pass or defeat the ground connections as this may
result in a hazardous condition.
15.Only personnel Trained and Qualified in the operation and service of Electrostatic
equipment are permitted to work upon the Application equipment and installation.
16.Any Personnel working within the application area, must wearing conductive
footwear. If personnel are required to wear gloves, these must also be conductive.
17.Ensure any Warning signs provided are prominently posted around the application
area so all personnel can read and adhere to the safety instructions.
18.For all Interconnection details of the equipment, please refer to page 9 - Fig 2 or
page 10 - Fig 3 for your appropriate application.

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
Fig 2

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
Fig 3

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
INSTALLATION
CONTROL UNIT –CONNECTION POINTS
Fig 4
Position
Description
CU1001
Remote trigger cabinet plug 6 pin Female (IP65)
CU1002
Electrostatic generating head cabinet plug 4 pin Female (IP65)
CU1003
Circuit Breaker (IP65)
CU1004
Mains electric input cabinet plug 4 pin Male (IP65)
CU1005
Not required for 1E & 2E Applications
CU1006
Terminal, Earth Post (IP65)
CU1007
Mains electric master on/off switch (IP65)
CU1008
Not required for 1E & 2E Applications
NOTE
The terminals used in the mains connector on the control panel of the unit are:-
POLE
PIN No.
Live
Pin 1
Neutral
Pin 3
Earth / Ground
Pin E
The method of disconnection from the mains electrical supply is by removal of the
mains lead plug from its respective supply socket.

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
INSTALLATION
CONTROL UNIT - PLUG IN CABLES
Fig 5
Position
Description
CUP1001
Remote Trigger plug 6 pin Male (IP65)
CUP1002
Electrostatic generating head plug 4 pin Male (IP65)
CUP1004
Mains electric input plug 4 pin Female (IP65)
REMOTE TRIGGER WIRING (CUP1001)
NOTE
For the remote trigger input signal for each channel to operate, the respective
Remote trigger on/off switch on the control facia, must be selected with the Red
LED below illuminated (see page 15 - Fig 8, position 7).
Fig 6
REMOTE VOLT FREE CONTACT
N/O
24V DC
PIN 1
6 PIN PLUG
PIN 6

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
INSTALLATION
CABLE COLOUR CODING FOR CONTROL UNIT
The cable colour coding used for the Control Unit and its supplied mains cable is as
follows:-
Pole
Designation
US/JAPAN
U.K.
Live
L
Black
Brown
Neutral
N
White
Blue
Earth / Ground
E
Green
Green/Yellow
For U.K. Equipment
The wire which is coloured GREEN and YELLOW must be connected to the terminal in
the plug which is marked with the letter Eor by the earth symbol, or coloured green or
green and yellow.
The wire which is coloured BLUE must be connected to the terminal which is marked
with the letter N or coloured black.
The wire which is coloured BROWN must be connected to the terminal which is marked
with the letter Lor coloured red.
IMPORTANT
When fitting a plug to the mains lead it is essential that it contains an
earthing/grounding contact and that this is connected. Under no circumstances should
this equipment be connected to a mains supply which does not include an
earthing/grounding wire and contacts. For example, wire extension leads, as used for
some domestic equipment, MUST NOT BE USED.

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
OPERATING PRINCIPLE
ELECTROSTATIC
The SAS control power supply transforms the 110/220 Vac into an adjustable
voltage operating from 3.5 to 13 Vdc.
The generator head converts the 3.5 to 13 Vdc into a negative charge up to
85kV, which is transferred onto the dust cloud which is then drawn towards the
grounded product being coated.
To obtain the maximum electrostatic efficiency the electrode needle on the
electrostatic generating head should be positioned towards the centre of the
drum in facing the tumbling product and powder cloud.
The product to be coated must be able to fully tumble and roll in front of the
generator head. If not, the electrostatic effect will not activate properly and will
give a poor performance.
The appropriate distance between the generator head and the product should be
between 20 to 45 cm (8" to 18")
GENERATOR HEAD
1. The part to be coated must be connected to the ground continuously.
2. Keep the atomiser clean.
3. Do not use the equipment if there is any damaged hoses, cables of connections.
4. Ensure that the distance between the electrode on the generating head and any
surrounding metal objects (including any application equipment and the Drum) is
at least 15cm (6”) or greater.
5. Ensure the generator head is installed and positioned correctly. (See page 14 - Fig
7)
Typical set-up image
Fig 7

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
OPERATING PRINCIPLE
CONTROL UNIT - FRONT PANEL
Fig 8
Position
Description
1
0-4 bar Pressure gauge
2
Not required for 1E & 2E Applications
3
Not required for 1E & 2E Applications
4
Not required for 1E & 2E Applications
S
Not required for 1E & 2E Applications
5
Not required for 1E & 2E Applications
6
Local on/off switch
7
Remote trigger on/off switch
8
Program information numbers
9
Microamp dial (orange)
10
Kilovolt dial (green)

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
START UP
ELECTROSTATIC CONTROLLER
1. Connect the SAS control to its electrical power source.
2. Turn the main power-supply ON/OFF switch to the ON position (see page 11 - Fig
4, CU1007).
3. To turn on the electrostatic effect, press the Local ON/OFF button on the panel
facia (see page 15 - Fig 8, position 6). The LED light below the button will turn
from Red to Green and the Kilovolt and Microamp dials will be illuminated.
4. The power supply emits a self-regulated voltage to the generator head from 3.5 to
13 Vdc. This regulated voltage is transformed into high voltage by the cascade
within the generator head and transported to the application electrode.
APPLICATION ADJUSTMENT
1. To obtain the maximum electrostatic efficiency the electrode needle on the
electrostatic generating head should be positioned towards the centre of the drum in
facing the tumbling product and powder cloud.
2. The product to be coated must be able to fully tumble and roll in front of the
generator head. If not, the electrostatic effect will not activate properly and will give a
poor performance.
3. The appropriate distance between the generator head and the product should be
between 20 to 45 cm (8" to 18")
4. Ensure that the distance between the electrode on the generating head and any
surrounding metal objects (including any application equipment and the Drum) is at
least 15cm (6”) or greater.
5. If required, adjust the rotational Speed and angle of the Drum unit to ensure the
product is tumbling but without causing damage.
6. Electrostatic effect.
The high voltage is shown in Green and will automatically adjust to the
maximum allowed for the application conditions.
The microamps is shown in Yellow is also automatically set depending upon
the application conditions.
7. Follow the Static Electricity Test (S.E.T.) as described on page 17, to check the
Electrostatic field within the application area.
NOTE
The electrostatic efficiency decreases quickly when generator head and cables are dirty
or damp, this will lead to poor performance. Please ensure the Generating head and
cables remain dry.

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
STATIC ELECTRICITY TEST
STATIC ELECTRICITY TESTER
Part No. 100-166
INSTRUCTIONS
Always “self-test” the tester (S.E.T) before you start.
Do this by touching both ends simultaneously.
The red light should illuminate indicating that the S.E.T. is functioning correctly.
ELECTROSTATIC TEST
1. Turn on the electrostatic generating head.
2. Always make sure you are holding onto an earthing point when doing this
test, or you are wearing conductive shoes.
3. Hold the S.E.T. with the screwdriver tip between the fingers. With the handle end
pointing towards the generating head, about 1m away, move towards the
electrode at the end of the electrostatic generator and you should see a strong red
light illuminate, being at it strongest when you are within 400-500mm from the
electrode.
4. If no red light appears then no static field is detected. Refer to the main manual
under the Troubleshooting section.

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
CLEANING METHOD
WARNING
Never switch ON the electric power supply unit during the washing and cleaning
operation.
All metallic parts located within and around the applicator head must be correctly
connected to the ground. Any floor coating must be electrically conductive and
grounded.
Do not stand upon wooden pallets or a non-grounded structure while cleaning.
DO NOT USE HIGH PRESSURE CLEANING SYSTEMS ON THE APPLICATION
EQUIPMENT AND CONTROLS.
CLEANING PROCEDURE
•The ON/OFF switches on the power supply and to the applicator head must be
OFF position before starting cleaning operation.
•Wait for 10 seconds before entering the spray area.
•Only apply a moderate amount of cleaning solution onto a clean soft cloth, or
bristle brush, to clean the applicator, generator head and cables.
•Hose down the complete system in place (CIP). There is no need to remove the
system for cleaning
•Wash thoroughly and dry completely with low pressure compressed air @ 2bar
(29psi)
•Wipe dry the generator head plus all cables carefully and thoroughly before
commencing production.
CAUTION: Synesthetic resins used in the fabrication of the electrostatic Atomiser
can react with certain cleaning agents. Check with Spice Application Systems.
CAUTION: avoid using the most toxic cleaning agents. Do not use chlorinates.
THIS IS VERY IMPORTANT.
IF NOT DRY IT CAN LEAD TO MATERIAL BUILD UP ON THE EQUIPMENT.
NEVER SWITCH ON THE ELECTROSTATICS WITH ANY CLEANING
MATERIALS REMAINING IN THE SYSTEM.
Before switching the electrostatic back ON, please check:
1. Check that the generator head, coating drum plus all hose and cables are
completely dry.
2. Check that all equipment within the application area is correctly installed and
positioned.

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SAS 1E & 2E - Electrostatic Probe Unit - APRIL 2020
SERVICING OVERVIEW
WARNING
The personnel involved in the electrostatic coating system servicing must be
trained and qualified. If you face any troubles which cannot be repaired after
consulting the Troubleshooting and Maintenance guides, do not try to start the
equipment. Consult your local authorised SAS distributor or SAS directly for
assistance.
1. The electric power supply must be disconnected before any servicing operation
(power supply unit switched off and isolated).
2. When turning off the Voltage, wait for 10 seconds before commencing work, so
that any electrostatic charge has time to reach ground.
3. Before disconnecting hoses, ensure that the system is no longer
pressurized, the air is turned off and that the electric current is also
switched off.
4. Do not soak or immerse the generator head or any plastic parts in a solvent. This
could result in damage and impair the safety circuits. If necessary, clean any
plastic parts with a soft brush soaked in a soapy water solution, after hosing down
and then wipe dry immediately.
5. Never leave components of the generator head immersed in cleaning solution.
6. Never use metal tools to clean the generator head.
7. Always store in a dry place.
8. After any repair and prior to turning on the power supply:
a. Ensure the generator head is correctly installed and positioned onto the
application unit.
b. Ensure all Earth wires are in place and positively connected to ground.