Spraying Systems AutoJet 1000+ User manual

1000+ Spray Control Panel Owner's Manual V1.1, English
P/N: ML001000PLUS
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Project No. _________
Serial No.: ____________
Model 1000
+
++
+
AutoJet Spray Control Panel
Owner’s Manual
Read this manual carefully before operating your Spray Control Panel.
Keep this manual for reference when the panel is in operation.
All safety related and operating instruction should always be followed.
Note:
This manual covers the complete Model 1000+ Spray System and all its versions, configurations and options.
Your system may vary based on the version, configuration and options that you have purchased.
Pictures in this manual may include options which are not part of your System Configuration.
Statements in this manual may describe options which are not part of your System Configuration.
Pictures in this manual may represent components which are different than those in your System Configuration.
Statements in this manual may describe components which are different than those in your System
Configuration.
The manufacturer reserves the right to make changes in this standard system without notification.

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Revision Sheet
Release No. Date Revision Description
V1 03/03/2018 First Release
V1.1 05/22/2019 Updated Product Images/minor changes

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Table of Contents
1 Introduction ............................................................................................................................................ 4
1.1 Product Specifications................................................................................................................... 4
2 Safety Information.................................................................................................................................. 4
2.1 General Safety Information ........................................................................................................... 4
2.1.1 Read and follow instructions ..................................................................................................... 4
2.1.2 Water and Moisture ................................................................................................................... 4
2.1.3 Servicing.................................................................................................................................... 4
2.1.4 Replacement Parts.................................................................................................................... 5
2.2 Warnings ....................................................................................................................................... 5
3 Installing the System.............................................................................................................................. 5
3.1 Unpack the Components............................................................................................................... 5
3.2 Mount the System ......................................................................................................................... 6
3.3 Electrical Connections................................................................................................................... 7
3.3.1 External Device Connections .................................................................................................... 7
4 Mounting the Spray Nozzles.................................................................................................................. 8
4.1 Notes on Nozzle Location ............................................................................................................. 8
4.1.1 Nozzle hook up kits – Tubing 12 ft. (3.6m) ............................................................................... 8
4.1.2 Electric nozzle cables – 10’ (3m) & 16.4’ (5m).......................................................................... 8
4.1.3 Trigger device cables – 16.4’ (5m)............................................................................................9
5 System Operation .................................................................................................................................. 9
5.1 Start up.......................................................................................................................................... 9
6 HMI operation and navigation ................................................................................................................ 9
7 External Input Offerings ....................................................................................................................... 18
8 Trigger Cable Offering ......................................................................................................................... 18
8.1 Required Input:............................................................................................................................ 18
8.2 Assembly Specifications: ............................................................................................................ 19
8.3 Level Switch Input ....................................................................................................................... 20
9 Optional Sensor Offerings ................................................................................................................... 20
9.1 Photoelectric Object sensor ........................................................................................................ 20
9.2 Thru Beam Sensor ...................................................................................................................... 21
10 Optional Electric Nozzle Cord Set Offering..................................................................................... 22
10.1 Assembly Specifications: ............................................................................................................ 23
10.2 Extension Cable .......................................................................................................................... 23
11 Troubleshooting .............................................................................................................................. 24
12 Faults............................................................................................................................................... 25
12.1 Re-calibrating the HMI ................................................................................................................ 26
13 Recommended System Maintenance ............................................................................................. 28
13.1 Liquid Components ..................................................................................................................... 28
13.1.1 Monthly: ............................................................................................................................... 28
13.2 Spray Nozzles ............................................................................................................................. 28
13.2.1 Daily: ................................................................................................................................... 28
13.2.2 Monthly: ............................................................................................................................... 28
14 Spare Parts List............................................................................................................................... 29
14.1 Recommended & Optional Spare Parts ......................................................................................29
15 Warranty Information....................................................................................................................... 30

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1Introduction
The 1000+ AutoJet timing System is a PLC based timing control unit. It has the following features.
•Two channel operation – Two independent timing channels, each with separate timing and trigger
modes.
•HMI based operation, all system settings can be adjusted from HMI.
•Recipe based timing, up to 20 recipes can be set by user.
•Can be used to operate almost any 24vdc Spraying Systems Co. electric spray nozzle or
solenoid.
•3 timing modes.
oVariable spray time mode – sprays only as long as trigger is present.
oRepeat spray mode – spray cycle is repeated on/off as long as trigger is present.
oFixed spray mode – sprays once for a fixed time (single shot).
•10ms timing resolution, up to 320 sec. max. on-times
•Variable and repeat modes have start/stop delays that are user settable (fixed only has start
delay).
•120V/60hz operation, plugs into any wall outlet (3 prong plug).
1.1 Product Specifications
•NEMA 4/IP66 polycarbonate enclosure.
•8” x 8” x 4” enclosure with easy mount flanges, stainless steel door latch.
•4.3” color HMI.
•120V/60hz operation, 5A fused internally, plugs into any 15A wall outlet plug (3 prong grounded
plug).
•4lbs., can be mounted anywhere.
•24vdc output to nozzles/solenoids, 3A max. available for the system (3 amps max. total combined
for both channels). An example of max. current allowed would be 3A for chan. 1 and 0A for chan.
2 or 1.5A for chan. 1 and 1.5A for chan. 2.
•Green LED - solid green for system OK, flashes green when fault present.
•40° F min., 104° F ambient maximum.
2Safety Information
2.1 General Safety Information
2.1.1 Read and follow instructions
All safety related and operating instructions should be read before the system is operated. Follow all
operating instructions.
Note: If the Model 1000+ AutoJet Spray Control Panel is used in a manner other than as described
in this Manual, protection afforded by the equipment may be impaired.
2.1.2 Water and Moisture
The control panels are rated NEMA 4/IP66, unless otherwise specified. The rating is only with the door
closed and properly locked. Being NEMA 4/IP66 rated, the control panel can withstand streams of water
directed at it; however we recommend avoiding spraying on the unit externally if possible.
2.1.3 Servicing
Do not attempt to service the 1000+ Spray Control Panel.
•For service, contact your local Spraying Systems Co. sales representative by calling
1-800-95-SPRAY (1-800-957-7729)

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•For corporate support contact 1-866-321-2250.
•Only authorized qualified service personnel should attempt to service the Control Panel.
oService by unauthorized personnel will void any and all warranties.
2.1.4 Replacement Parts
The 1000+ AutoJet Spray Control Panel has been designed with components that work together to
provide the best system performance. When the system requires replacement parts, only Spraying
Systems Co. recommended components should be used to maintain proper system operation and safety.
2.2 Warnings
WARNING: It is important to recognize proper safety precautions when using a pressurized spray
system. Fluids under pressure can penetrate skin and cause severe injury.
WARNING: When dealing with pressure applications, the system pressure should never exceed the
lowest rated component. Always know your system and all component capabilities, maximum pressures
and flow rates.
WARNING: Before performing any maintenance, make sure all electrical, air and liquid supply lines to
the system are shut off and /or disconnected.
WARNING: The use of any chemicals requires careful control of all worker safety.
WARNING: 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.
WARNING: Spraying Systems Co. strongly recommends the use of appropriate safety equipment when
working with potentially hazardous chemicals.
This equipment includes but is not limited to:
•Protective hat
•Safety glasses or face shield
•Chemical-resistant gloves and apron
•Long sleeve shirt and long pants
WARNING: Always remember to carefully read the chemical manufacturer’s label and follow all
directions.
3Installing the System
3.1 Unpack the Components
The system components come carefully packaged to protect them from damage and consist of the
enclosure, which contains the electronic and pneumatic controls, plus a separate box which contains
accessories.
Depending on your system configuration, the following additional accessories may be included:
o Trigger input cable(s)
o Photoelectric object sensor with cable and bracket
o Thru beam sensor with cables and brackets
o Hand held trigger switch
o Input signal cable for remote Duty Cycle control
o Fault output cable kit
o PulsaJet
®
nozzle or electric spray nozzle connector cable(s)
o Spray nozzle(s)
o Spray nozzle hook up kit
Please check the packaging slip for confirmation of contents and quantity of packages. Panels sold with
a pressure pot will be shipped in multiple packages.

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NOTE: The packing boxes may contain exposed cables and hoses. Always use caution when opening
the boxes to avoid accidental damage or slicing of various components.
Remove everything from the boxes and carefully remove any packaging material protecting the
components.
Caution should be used when using a knife to cut the packaging. Be careful not to cut through and
scratch the panel.
Verify that the accessories required for your specific system configuration are included. If anything is
missing, or if there are any questions, contact Spraying Systems Co. Customer Service immediately.
3.2 Mount the System
Find a good place to mount the spray control panel. A convenient location within a reasonable distance
of your spray application. Additionally the system should be located within a reasonable distance to an
easily accessible and properly grounded power outlet. The unit must be installed in such a manner that
when the cord is connected, the plug can be easily reached and not difficult to remove it from the outlet.
It needs a 120vac 3 prong grounded outlet nearby and mount using the following template for mounting.
Use good mounting practices. It should be mounted using good hardware in a place where the enclosure
will not be subjected to direct spray or mist from the nozzles. It should be mounted horizontally.

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3.3 Electrical Connections
•The controller has the following connections.
o120vac input, 3 prong plug.
oTrigger input, 1 per channel. These are the two M12 male connections on the bottom of
the enclosure marked TRIG 1 and TRIG 2. Most of the trigger options we offer come
prewired from the factory so they are plug and play. If you are doing the wiring yourself,
the two trigger inputs are a “dry contact” with contact closure between pins 3 (blue wire)
and 4 (black wire). See wiring diagram for more detail
o24vdc output to nozzles and solenoids, 1 per channel. These are the two M12 female
connections on the bottom of the enclosure marked OUT 1 and OUT 2. Most of the
cable options we offer come prewired from the factory so they are plug and play. If you
are doing the wiring yourself, the two nozzle outputs are between pins 1 (brown wire) and
3 (blue wire). See wiring diagram for more detail.
oFloat switch input, 1 per channel. These are the two M8 male connections on the bottom
of the enclosure marked FLOAT 1 and FLOAT 2. These are for normally open or closed
float switches. You use pins 3 and 4 (the blue and black wires) in this cable. See wiring
diagram for more detail
3.3.1 External Device Connections
Cable devices required for operation, these are typically quoted and supplied with the system.
•Trigger options that come prewired, plug-n-play operation, all cables included, typ. 5 meter
lengths.
oManual hand pendant SW001550M12HT
oHeavy duty foot switch 040TS04000130W0
oElectrical sensor kits (wired for NPN operation)
Photoelectric, 040TS04000014W0
Through beam 040TS04000028W0

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Proximity 040TS04000118W0
Laser, long sensing distances 040TS04000087W0
Laser, short sensing distances 040TS04000135W0
oTrigger extension cable, 5 meter, LEXXSD4FD4M005P
•Trigger option for custom wiring.
oBare lead trigger cable for custom wiring to external devices (PLC’s, switches, etc.)
LE00M12F5M
•Nozzle output cables, LEXXSD3M83F010P, 1 meter; LEXXSD3M83F020P, 2 meter;
LEXXSD3M83F030P, 3 meter; LEXXSD3M83F050P, 5 meter. All are M8(f) x M12(m).
•Nozzle output cable, bare lead, 5 meter, 50699-5-PVC.
•Nozzle output junction block kit , for connecting up to 4 nozzles JCPCNS000005-00_AC01.
•Nozzle output junction block kit, for connecting up to 8 nozzles JCPCNS000004-00_AC01.
4Mounting the Spray Nozzles
•The nozzles should be mounted where they can be easily maintained. Spraying Systems Co.
has a number of mounting options, see your local salesman for more information. We supply
most of the cables and junction blocks required for easy setup and operation.
Locate and mount the spray nozzles for your spray application. Depending on your application the spray
nozzle lines and connections will vary. It is recommended to run the lines starting from the spray nozzles
to the system for easier adjustment of lengths of the tubing. Note length should be kept to a minimum to
reduce pressure drop.
4.1 Notes on Nozzle Location
When locating the panel in relation to the spray nozzles note these typical lengths of connecting items.
You may or may not have these items depending on your project and order.
4.1.1 Nozzle hook up kits – Tubing 12 ft. (3.6m)
If your system was order with optional nozzle hook up kit the design of the hook up kit allows for 12’ of
tubing from the nozzle to the system for a single nozzle hook up kit. For multiple nozzle hook up kits they
are designed to provide 12’ (3.6m) of tubing to the manifold and 12’ (3.6m) of tubing from the manifold to
the system.
4.1.2 Electric nozzle cables – 10’ (3m) & 16.4’ (5m)
All systems design to use electric nozzles comes with the required cables. IF your system did not come
with these cables please contact your local sales engineer.
•For a single electric nozzle system, the cable length is 10’ (3m) [Cable P/N LEXXSD3M83F030P,
for AA10000 series; P/N LE00M12MMDIN3MU for AA250 series]. For multiple electrical nozzles
the system comes with cable from the nozzle (one per nozzle) to a junction block that is 10’ (3m)
[Cable P/N LEXXSD3M83F030P, for AA10000 series; P/N LE00M12MMDIN3MU for AA250
series] and a cable from the junction block to the system that is 16.4 ft (5m) {Cable P/N
LE00M12M5M].
•If longer length cables are required we offer an extension cable that is 16.4’ (5m) [Cable P/N
LEXXSD4FD4M005P].
oThis cable can be used to go between the nozzle cable and the junction block or the
junction block cable and the system.
oThis cable can also be used to extend the trigger devise cable lengths stated below.
oNote due to voltage drop we recommend keeping the cable length to a reasonable
length. Never attempt to chain more than four (4) cables together. Electric spray nozzle
speed and performance will suffer.

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4.1.3 Trigger device cables – 16.4’ (5m)
All systems must be purchase with a trigger device to activate the system during operation. All of our
offerings have a cable length of 16.4’ (5m).
•If longer length cables are required we offer an extension cable that is 16.4’ (5m) [Cable P/N
LEXXSD4FD4M005P].
oThis cable can be used to go between the trigger cable and the system.
oThis cable can also be used to extend the electric nozzle cable lengths stated above.
5System Operation
5.1 Start up
To begin using the system, power up by actuating the power switch on the bottom of the control panel
oGreen LED on the front of the panel will illuminate when power is on.
6MI operation and navigation
The HMI has an easy to follow layout with recipe based timing. It will boot to the Home screen.
•Home Screen
For both channels it will show recipe number active, recipe name and spray status and if local trigger
option is active, an on/off button for local triggering off the HMI. Common to all screen (lower right hand
corner) is the back, home and menu buttons . The back button gets you back one
screen, the home button goes to the home screen and the menu (hamburger) button goes to the main
menu screen
•Recipe configuration
•press menu button

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Press Recipe Configuration
Create the recipe – enter recipe #, name, timing mode, and the timing required for the mode you are
using. The three timing modes you can choose are:
oVariable spray time mode – is used to create spray applications with variable length. The lengths of the
spray depends on the specific time delays between the rising and falling edge of the trigger input. Spray
follows trigger according to user settings. The system will spray after trigger goes high then stops when
the trigger is low. For this timing mode you enter “Start Delay” and “Stop Delay”. An example of this
timing is shown in the following picture.
o

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oRepeat spray mode – Repeat is used to create spray applications of specific time during a variable length
spray period. The lengths of the spray depends on the specific time delays between the rising and falling
edge of the trigger input. Spray follows trigger according to user settings. The system will spray after
trigger goes high then stops until next trigger event. So for every trigger, there are repeated spray
events. For this timing mode you enter “Start Delay”, “Interval Off”, “Interval On”, and “Stop Delay”. An
example of this timing is shown in the following picture.
o
oFixed spray mode – (also called single shot mode) is used for a single spray event. The system will spray
after trigger goes high then stops until next trigger event. In other words for every trigger, there is a single
spray event. For this timing mode you enter “Start Delay” and “Spray Period”. An example of this timing
mode is shown in the following picture.
o
For all three modes, delays are for where the nozzle is not in line with the sensor so they can be used to
adjust when the spray starts or stops in relation to the trigger signal. When there is a start delay value of
0 sec., the spray will start immediately after the trigger signal is sent to the controller and conversely if the
stop delay is set to 0 sec., the spray will stop immediately after trigger signal goes low.
All delay values can be set from 0.00 to 320.00 sec.. , spray times can be set to 0.10 to 320.00 sec.
Screen Capture, there is a convenient screen capture function on the recipe configuration screen. Once
you’ve configured a recipe, tap the “Screen Capture to .jpg” button. This will save a screenshot of the
recipe on a fat32 formatted USB stick that you’ve inserted into the USB-A port on the back of the HMI.
You can save these images for easy recipe reference for line operators or engineers.
Once you are finished configuring the recipes, tap the menu button to continue the configuration. This will
bring you back to the main menu.

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Tap System Configuration, this will bring you to the following screen.
You have three buttons on this screen.
Remote/Local I/O, Digital Input Polarity and Password Settings. Press the first one.

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On this screen you set the status of your trigger and sensor inputs.
1. Trigger Channel 1 you can toggle between remote(X0) and local. When it shows remote(X0) the PLC
is looking for the trigger input from an external sensor. When you are using one of our sensor kits,
you must set this to ‘remote’. When this toggle is set to local, the triggering option is done via the
HMI. An on/off button appears on the Home screen when this is set to ‘local’.
2. Trigger Channel 2 this is the same as above but for trigger channel 2. It gives you the option of
triggering channel 2 remotely or local button.
3. Channel 1 Tank Low Sensor, this enables or disables the tank low input. When enabled, it allows the
PLC to see this input, when set to disabled, the PLC will not see a tank level input.
4. Channel 2 Tank Low Sensor, same as above for channel 1 tank low sensor.
Once this screen is configured, touch back button to go back to Remote/Local I/O screen then touch
Digital Input Polarity button. This brings you to this screen.

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On this screen you set the polarity of your digital inputs to normally open or normally closed. Typically
these are set to normally open. Note, if you have enabled the tank empty inputs (on remote/local I/O
screen) and you set the polarity of these inputs to ‘normally closed’ you will get a fault showing on the
HMI and the green led on the front panel will flash showing an active fault condition.
Once the I/O is configured, press back button to go back to System Configuration screen and press
Password Settings button.
Out of the box, the default password setting is shown above (never require passwords). The HMI will
never prompt the user for a password. If you see a need to change this there are 3 additional password
levels you can set. Each level has its own password. See below for default password table.

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The password protection levels are:
Level 0 – Always require password - The highest level of protection, every action will require the
password for this level.
Level 1 – Allow recipe selection – the user on this level can only change recipes.
Level 2 – Allow recipe edit – a user on this level can edit recipes and also select recipes.
Level 3 – never require password – as discussed, this level allows full access to all functionality.
The password table is set to the following and can be changed only by user level 3. Press ‘configure
passwords’
And the following password table pops up.

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The top line of this table is for level 0 and its default password is 00000000. This is the password you
give out to the low level operators that can only change recipe number and nothing else. The same goes
for the remaining 3 levels. The top level 3 password is 33333333 (levels above that are shown and will
work for level 3 access.
Things to remember regarding passwords and password levels:
Level 0 is the lowest and level 3 is the highest level.
Once a password is entered, the security level will remain at that level until another password is entered.
For example, if the line manager needs to go tweak some of the high-level settings, he/she must use level
3 password. Once he/she is finished the HMI will remain in level 3 (no passwords required) until a lower
password level is chosen.
In case of errors or if passwords have been forgotten, the top level password is 77777777.
About screen – this screen contains the HMI and PLC firmware versions.
Maintenance/Purge – used for cleaning and purging lines. Pressing button next to the corresponding
channel will lock on the output for that channel until it is again pressed to stop the spray to that channel.

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Diagnostics screen- this screen shows useful information regarding system information. Inputs and
outputs are shown. This is typically used during the initial setup and for trouble shooting. E.g. setting up
trigger sensors, you can view if the system is actually seeing the trigger signal (0 when not, 1 when
trigger active).
HMI functions menu – this menu is full of small tweaks that can make the HMI easier to use.
HMI Brightness/Contrast – Adjusts MHI brightness
Screen Calibration –If touch points seem different from where you touch, this function can recalibrate the
touch points.
Recipe table save to USB – future.
HMI time/date – For setting RTC in HMI.
HMI system menu – Base level menu in HMI software, not normally used.
Recipe table import from USB – future.
Safely remove USB – For safely removing USB stick.
UBS present – Shows 1 for USB present, 0 for no USB.

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That’s it, your system is setup. You can always go back and change things according to this manual.
7External Input Offerings
The system may be purchased with the following input components.
Description Connects
To
Part Number
Trigger Cable – Flying leads - 16.4’ (5m) length Trig. LE00M12F5M
Hand Pendant Trigger - 16.4’ (5m) length Trig. SW001550M12HT
Object Sensor - Photoelectric - 16.4’ (5m) length with mounting bracket Trig. 040TS04000014W0
Object Sensor - Thru Beam - 16.4’ (5m) length with mounting bracket Trig. 040TS04000028W0
Extension Cable – Connector - 16.4’ (5m) length M12FxM12F, 4 pole Trig./Main LEXXSD4FD4F0050
Input Signal Cable - Flying lead - 16.4’ (5m) length, M8 x bare leads, 4 pole 4-20mA LE00M8M5M
Trigger Interlock Cable, M8 Female, 4 pole, bare leads, 16.4’ (5m) T int. LE00M8F5M
Junction Block - 4 connectors – with cable, 16.4’ (5m) length, M12 male Main JCPCNS000005-00_AC01
Junction Block - 8 connectors – with cable, 16.4’ (5m) length, M12 male Main JCPCNS000004-00_AC01
PulsaJet Nozzle Cable to Controller of Multiport Junction Block 9.8’ (3m) length Main LEXXSD3M83F030P
AA250 Nozzle Cable to Controller of Multiport Junction Block 9.8’ (3m) length Main LE00M12MMDIN3MU
Details on various components are explained in the following sections.
8Trigger Cable Offering
Optional trigger cable offering: Un-terminated flying lead cable and connector.
8.1 Required Input:
oPart Number - LE00M12F5M - Trigger Cable
oNPN – Switch to 0 VDC to turn on spray trigger.
•Requires NPN Sensor or switch configured to NPN
o19 – 30 VDC

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oConnects to the connector labeled “Trig.” On the bottom of the panel.
8.2 Assembly Specifications:
oPanel connection: Trig 1 or Trig 2
oCable: 16.4 ft. [5 m] cord length
oFlying Leads
oConnector end – M12 4 pin female
Color Code
P n # Color Descr pt on
1 Brown + 24VDC (only used for sensors)
2 Wh te 0 VDC (only used for sensors)
3 Blue 0 VDC
4 Black
Input X0 or X1
Note: Connect pins 3 & 4 with switch or relay contact to initiate trigger.
WARNING: Never connect pin 1 (24vdc) to any other pin. Doing so could cause injury or
equipment damage. (Cut the brown and white wire if you're not using them)

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8.3 Level Switch Input
The 1000+ controller features a digital input for a level switch (one per channel).
This feature allows you to wire in a normally open or normally closed (configurable in software)
level switch from a liquid tote or tank. To use this feature you need our cable part number
LE00M8F5M.
oPanel connection: float 1 or float 2
oCable: 16.4 ft. [5 m] cord length
oFlying Leads
oConnector end – M8 4 pin female
Color Code
P n # Color Descr pt on
1 Brown not used
2 Wh te not used
3 Blue To level sw tch (polar ty not mportant)
4 Black To level sw tch (polar ty not mportant)
9Optional Sensor Offerings
Optional sensor offerings included the following. Note that we are not a sensor manufacture and that
these have been selected for their versatility and quality. They should be selected based on what’s best
for your application:
9.1 Photoelectric Object sensor
Infrared – direct reflection sensor with cable and connector
Kit Number: 040TS04000014W0
Sensor Specifications:
•Photoelectric sensor – Infrared – direct reflection sensor with cable, connector, and bracket.
oNPN – NO + NC
o35 inch [900 mm] sensing range
oSetting distance adjustable between 6 and 36 inches [150 and 900 mm]
oWorking temperature range = -4° F to 158° F [-20° C to 70° C]
oIP67; CE rated
Assembly Specifications:
oPanel connection: Trig
oCable: 16.4 ft. [5 m] cord length