Spraying Systems AutoJet ES250 User manual

AutoJet® ES250
Electrostatic Chain
Oiler System
ML00ES250F
spray.com
OWNER’S MANUAL

1. Preface ········································································································································ 3
1.1 Important ········································································································································ 3
1.2 How To Use This Manual················································································································ 3
2. Safety ·········································································································································· 3
2.1 General Safety Informaon············································································································ 3
2.2 Unpacking the System····················································································································· 4
3. ES250 Overview ··························································································································· 5
3.1 Electrostacs Spraying Overview··································································································· 5
3.2 System Components and Installaon Requirements····································································· 5
4. Electrostac Spray Control Panel·································································································· 6
4.1 Mounng the Panel and Door Diagram ························································································· 6
4.2 Connecng the High Voltage Cable································································································ 7
4.3 Circuit Board (PCB) and Terminal Block Diagram··········································································· 8
4.4 Input Details ································································································································· 11
4.5 Output Details ······························································································································ 13
4.6 Potenometers ···························································································································· 16
4.7 System Modes······························································································································ 16
4.8 Oponal PCB Inputs and Connecons ························································································· 18
4.9 Verifying the Spray Control Panel Set Up ···················································································· 19
5. Fluid Reservoir Assembly ··········································································································· 20
5.1 Mounng and Posioning············································································································ 20
5.2 Fluid Reservoir Connecons········································································································· 21
5.3 Lubricant Pump ···························································································································· 22
5.4 Components ································································································································· 23
5.5 Air Pressure Regulator·················································································································· 23
5.6 Parculate Filter··························································································································· 25
5.7 Verifying the Fluid Reservoir Assembly Set Up············································································ 25
6. Electrostac Chain Oiler Spray Nozzle························································································· 26
6.1 Nozzle Overview··························································································································· 26
6.2 Nozzle Connecons······················································································································ 27
6.3 Nozzle Disassembly Procedure ···································································································· 27
6.4 Nozzle Conguraon and Adjustment························································································· 28
7. Faults and Troubleshoong········································································································ 29
7.1 Faults and Fault Codes ················································································································· 29
7.2 Fault LED Status···························································································································· 30
7.3 General System Troubleshoong································································································· 32
7.4 Arc Fault Troubleshoong············································································································ 33
8. Spare and Replacement Parts····································································································· 34
TABLE OF CONTENTS

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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

4
• 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.

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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