Spraying Systems AutoJet ES2500 User manual

AutoJet® ES2500
Electrostatic
Manifold System
OWNER’S MANUAL
MI102012-000
spray.com

TABLE OF CONTENTS
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. System Overview·························································································································5
3.1 Introducon ····································································································································5
3.2 Product Features And Specicaons······························································································5
3.3 Encoder Kit (Oponal)·····················································································································5
4. Control Panel································································································································7
4.1 Control Panel Overview ··················································································································7
4.2 HMI Overview ·································································································································8
4.3 Purge/Clean Sengs·······················································································································9
4.4 Operang (Home Screen) ···············································································································9
4.5 Recipe Setup ·································································································································10
4.6 System Conguraon····················································································································10
4.7 CH1 Conguraon·························································································································11
4.8 Motor/Driver Informaon ············································································································12
4.9 Alarm Sengs·······························································································································12
4.10 Monitor IO Sengs······················································································································14
4.11 Help Sengs ································································································································15
5. Fluid Delivery Cart ·····················································································································16
5.1 Overview·······································································································································16
5.2 Tank···············································································································································16
5.3 Pump·············································································································································16
5.4 Level Sensor ··································································································································16
6. Manifold ····································································································································18
6.1 Overview·······································································································································18
6.2 Mounng·······································································································································18
6.3 Hook-Up ········································································································································19
6.4 Control Funcons··························································································································20
6.5 Nozzle Conguraon·····················································································································21
6.6 Start-Up Procedure·······················································································································21
6.7 Manifold Disassembly···················································································································22
6.8 Electrostac Manifold Diagram ····································································································24
7. Troubleshoong··························································································································25
8. System Maintenance···················································································································27

3
1.1 IMPORTANT
The AutoJet® ES2500 Electrostac Manifold System 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.
SECTION 1
PREFACE
SECTION 2
SAFETY
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 in-
struc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.
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
would be:
• Using incompable materials/damaged parts
• Making unauthorized modicaons/using unapproved auxiliary equipment

4
• 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
• Safety glasses or face shield
• Chemical-resistant safety gloves and apron
• 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 potenal hazards involved.
2.2 UNPACKING THE SYSTEM
The system components come 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.

5
3.1 INTRODUCTION
The Spraying Systems Co. ES2500 is an Electrostac System that ulizes a low ow rate and negavely charged uid to produce
electrostac spraying. The system’s purpose is to deliver a controlled spray with a very high transfer eciency. System applica-
ons include spraying various oils and other coang or lubricang uids onto neutrally charged and grounded metallic targets.
In electrostac spraying, a negave charge is introduced into a uid in the nozzle body using direct contact charging. When this
charge is applied, it causes the uid to also acquire a negave charge. This causes the uid molecules to repel each other, follow-
ing the principle that like charged molecules will repel and opposite charged molecules will aract. This applied negave charge
also causes the uid to be over the Rayleigh limit, which means it will form into droplets as it exits the nozzle orice.
Aer leaving the nozzle orice, the newly formed droplets connue to repel each other—causing the already small droplets to
split evenly into even smaller droplets. This process will connue unl the repulsive force between uid molecules is no longer
strong enough to break the surface tension and split the droplet again.
The 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 uid droplets towards this target, thinly and evenly
coang the target surface. The average nal drop diameter produced by the Electrostac Manifold is less than 10 microns.
3.2 PRODUCT FEATURES AND SPECIFICATIONS
The ES2500 Electrostac Spray System consists of three main component groups:
• System Control Panel
• Fluid Delivery Cart
• Electrostac Manifold
This manual contains general specicaons and informaon for the ES2500 Electrostac Manifold System. This includes product
overviews, installaon, operaon, maintenance, and troubleshoong informaon.
SYSTEM USAGE
• The ES2500 is designed to run connuously and provide electrostac uid applicaon with high transfer eciency
• Intended uses include spraying a lubricaon oil or a release agent onto a specic metallic target .
• The ES2500 system control panel features a 10” touchscreen HMI
o Operators can control uid ow rate and applied voltage
o System soware has been customized for electrostac spraying, including specic faults and alarms
• The system features two strainer valve assemblies, which allows one strainer to be accessible for cleaning during system
operaon. This limits system downme for maintenance and allows for connuous system use.
3.3 ENCODER KIT (OPTIONAL)
This system can be programmed to use an encoder and control the system with units of distance instead of ming.
Speed/Encoder sengs require a connected line speed encoder. There are two encoders that Spraying Systems Co.
oers, but the customer can also supply their own.
ENCODER SELECTION
The hollow sha encoder will mount in the conveyor, while the wheel and pivot
stye encoder requires the wheel to rest on the conveyor surfaces to measure the
line speed.
SECTION 3
SYSTEM OVERVIEW
M12 (f) x 4 pole M12 (f) cable 5m
(Included in both kits)

6
HOLLOW SHAFT ENCODER
Calculang the calibraon constant—K Factor (pulses/)
K = PPR / CIR (.) = PPR / (PI*DIA)
*Use diameter of drive/tail pulley that encoder is aached to.
K = PPR (*D1/D2) / (PI*D2)
*Used with dual pulley conguraon. D1—Drive/Tail pulley, D2—Secondary pulley encoder is aached to.
Gear rao = D1/D2
WHEEL AND PIVOT MOUNTED ENCODER
Calculang the calibraon constant—K Factor (pulses/)
K = PPR / Wheel CIR (.)
SPECIFICATIONS
Resoluon (PPR) 1024
Output 5-26V push-pull
Input 5-26V
Bore 5/8” hollow bore w/ tether
Bore Inserts Metric 11 mm, 12 mm, 14mm
Bore Inserts Standard 1/4”, 3/8”, 1/2”
Enclosure Rang NEMA4/IP65 (Dust Proof,
Washdown)
SPECIFICATIONS
Resoluon (PPR) 1024
Output 5-26V push-pull
Input 5-26V
Bore 3/8” sealed sha
Wheel Circumference (CIR) 12”
Enclosure Rang IP67 w/ sha seals

7
4.1 Control Panel Overview
The ES2500 Control Panel is used to adjust the parameters of the manifold and adjust the sengs on the uid delivery
cart. Using the HMI screen sengs you can adjust the operaon and conguraon sengs.
PANEL POWER REQUIREMENTS :
Voltage– 120VAC, 3Ph
Frequency- 60Hz
Current– 20A max
ELECTROSTATIC PANEL FEATURES:
• 10” HMI Touch Screen display
• Customizable spray parameters
• Washdown rated
• Three (3) Color Stack Light
• Audible alarm
• Emergency stop buon
• Start/Stop Buon
• System Trigger Buon
SYSTEM CONTROL PANEL LABELED DIAGRAM
SECTION 4
CONTROL PANEL
When the emergency stop buon is
pressed this screen will pop up.

8
Operang Screen Buons
Note: If included in your conguraon, CH2 buons operate in the exact same way as CH1 buons.
Buon Descripon
Channel Current Status:
This buon allows the operator to toggle the system in to run or standby mode. The
buon will appear green while the system is operang.
Recipe Selecon:
The name of the currently selected recipe will appear in the text window. Use the up
or down arrow buons if you need to select a new recipe.
Electrostac Status:
Displays the current operang status of the Electrostac system. This image shows
how the buon is during standby state.
The buon will be green during system operaon.
Motor Idle:
This buon will be red when the motor is o and will be green while the motor is
running.
Purge/Clean:
This buon brings up the system ‘Purge/Clean’ sengs. See the Purge/Clean secon
for more informaon.
ES2500 Menu:
Whenever this buon is visible in the top right-hand corner of the HMI, operators
can open and make selecons from the navigaon menu.
4.2 HMI OVERVIEW
The HMI screens are shown with addional features or opons that may not be included with your system conguraon.
First starng up and aer any system reboot, the Operang screen will load as the system default screen. From the
‘Operang’ screen, you can:
• Trigger Channel standby and run
• View and change the currently selected recipe
• View the voltage setpoint
• View the line speed (If Encoder is connected)
• View the ow rate setpoint
• View the Electrostac system status
• View if the motor is currently running
• Access the Purge/Clean settings

9
4.3 PURGE/CLEAN SETTINGS
The ‘Purge/Clean’ features allows for pump operaon and liquid ow without the acvaon of the High Voltage Pow-
er Supply (HVPS) and Electrostac components.
PURGE
The purge funcon purges the uid lines of air by running the pump to ll the lines with uid. Purge mode should be
run unl uid begins to drip from the manifold nozzles. The purge funcon is to be used during inial installaon to ll
the uid lines, and before each system run when the uid lines have been previously drained. Operators can set the
purge speed in gallons per hour (GPH), and should set the pump speed within the upper range of its maximum ow
seng.
CLEAN
The system should be ushed and cleaned with a fre-
quency determined by system operators. It is suggested
to ush and clean the system at the end of each product
run.
The clean funcon should be ulized when cleaning and
ushing the system. This is because the clean funcon
does not acvate the HV connecon. This allows water
to ush the system.
Operators can set the ow rate for the clean cycle in GPH
and set a me for the duraon of the funcon.
Begin by draining the tank of uid by opening the discharge port of the 3-way
valve at the boom of the tank. Rinse the tank aer uid has been drained.
Add water and a detergent (if desired) to the tank to run through the system
and clean the system lines.
4.4 OPERATING (HOME SCREEN)
All system sengs opons can be accessed through the ES2500 Menu buon at the top of the HMI screen, allowing
system operators to quickly access the sengs and informaon that they need.
The following secons will explain the funcon of each navigaon menu opon.
RETURNING TO THE OPERATING (HOME) SCREEN
Return to the ‘Operang’ screen at any me to see the current system conguraon.
Purge/Clean screen with the oponal two (2)
Channel set up.
Operang screen shown here with oponal CH 2 (second channel) conguraon.

10
4.5 RECIPE SETUP
The Recipes feature allows you to create and save your commonly used spray parameters. The system supports the
creaon and storage of up to 16 customized recipes. Switching between premade Recipes allows for much quicker
transions when changing batches or products that may require dierent spray parameters. Each individual recipe
allows you to:
• Create a name
• Enter the owrate setpoint in gallons per hour (GPH) or based on mL per Sq. Ft. (line speed)
• Enter the Electrostac voltage setpoint in kV
• Set the pump priming me
• Set the desired spray width in inches
4.6 SYSTEM CONFIGURATION
The ‘System Conguraon’ seng allows operators to set system parameters for operaon. For each channel, the op-
erator has control over opons that will aect the system output.
Recipe Setup screen
System Conguraon screen with Mulchannel (2 channels) enabled.

11
4.7 CH1 CONFIGURATION
CH1 HIGH VOLTAGE FEEDBACK SETUP
Note: Ch2 conguraons setup are the same as Ch1 con-
guraon setup.
The operator can set the max voltage output in kV for both the
HVPS and PLC.
CH1 LINE SPEED SETUP
If you are using a line speed encoder with the ES2500, this con-
guraon will allow you to use the device with the system.
See Encoder Selecon for more informaon about encoders.
CH1 HV AMPERAGE FEEDBACK SETUP
This screen allows the operator to set an amperage alarm, if
the amperage exceeds this amount the system will fault.
CH1 LEVEL SENSOR SETUP
Relying on the input data from the uid level sensor, this screen
will allow operators to congure system faults and alarms will
occur based on the uid level in the tank.
Operators can set two separate alarms, the rst alarm will trig-
ger when the uid reaches the set low level percentage, and
the second will trigger when the uid reaches a level that is no
longer safe for system operaon. A tolerance me opon is
also editable.

12
4.8 MOTOR/DRIVER INFORMATION
The Pump Motor and Drive Informaon secon provides operators with current operaonal informaon for the system
motor and sets certain system parameters and view/reset the trip meter.
It allows the operator to set the degrees per step (Deg Per Step) and the milliliters per revoluon (mL/Rev) for the
pump. The informaon on this screen can be useful when troubleshoong the motor.
4.9 ALARM SETTINGS
The ES2500 system noes operators of acve and ongoing alarms at the top of the HMI screen and via stack light illu-
minaon. The Acve Alarms screen, as seen below, lists the me of the fault and the alarm fault code. This screen can
be accessed through clicking the alarm popup at the top of the screen, or through clicking Alarms in the Navigaon
menu. Once resolved, alarms can be cleared by pressing the Alarm Reset buon.
See Troubleshoong secon for more informaon.
Acve Alarms Screen
Motor/Driver Info Screen

13
ALARM HISTORY SCREEN
The Alarm History screen allows operators to view any ongoing or past alarms. This screen will log the me that an
alarm occurs, as well as the specic alarm fault code.
ALARM SETTINGS
Alarm sengs allows operators to adjust the parameters for system alarms. Most alarms have tolerance mes that
are user-controlled sengs. The tolerance me determines how long a certain fault can occur before triggering an
alarm. Operators can also disable certain alarms if desired.
Stack Light
The Stack Light serves as an easy visual indicaon for the current system status of the ES2500. The Stack Light fea-
tures three possible nocaon lights: green, amber, and red. The green and red lights can appear as either a solid or
ashing illuminaon.
• Green: When the stack light is green, it represents normal system condions.
- Solid green- the system is ready for operaon
- Flashing green- occurs during system operaon.
• Amber: When the stack light is displaying an amber light, it represents that the system is not ready for operaon.
• Red (Warning): The stack light appears red when
there is a system fault and the Emergency stop
buon is deployed.
- Solid red- a standard system fault
- Flashing red- a crical system fault.

14
4.10 MONITOR IO SETTINGS
When Monitor IO is selected from the Navigaon menu, the rst screen you will see is “Embedded IO Monitor” as
seen below. This screen provides live readings of both the analog and digital aspects of the PLC. This screen can pro-
vide useful informaon when troubleshoong system components.
PLUGIN RELAY OUTPUT
This screen displays output relays that can also be toggled on or o. These opons can be helpful for troubleshoong
purposes.
IO Informaon

15
ANALOG IO
The Analog IO screen displays current analog values for the controller, which can be useful for troubleshoong pur-
poses.
4.11 HELP SETTING
Selecng ‘Help’ from the navigaon menu will bring up a screen that displays system informaon, access the HMI OS,
Screen Map, and change password proles.
SCREEN MAP
The Screen Map displays all possible screens
within the ES2500 menu. It allows operators to
select any sengs.
The ‘Help’ screen also displays the current PLC soware version.

16
5.1 OVERVIEW
The uid tank features a level sensor to monitor and produce a fault when the
uid falls to a low level. The tank also features a 3-way ball valve at its outlet for
uid draining and cleaning purposes.
Fluid Delivery Cart Dimensions: 40.500” x 31.263” x 54.502”
5.2 TANK
Tank is mounted using 4 3/8” -16 screws
TANK SPECIFICATIONS:
Capacity: 15 Gal, Cone Boom
Material: Polyethylene
Dimensions: 16” x 16” x 24”
5.3 PUMP
The ES2500 pump comes standard with one pump to power uid delivery to the Electrostac Manifold(s). It has a mo-
tor driven, progressive cavity pump, with speed adjusted by the ES2500 control panel for desired ow.
PUMP SPECIFICATIONS:
Max ow: 10 GPH
SET-UP
Pump gets fed from the tank with a 3/4” Tygon hose.
ATTENTION: Viscosity of the uid being sprayed may have a signicant impact on the pump specica-
ons.
5.4 LEVEL SENSOR
The level sensor sends a signal when the tank gets low to let the control panel know when to shut o the system to
prevent the pump from running dry and becoming damaged. The level sensor gets wired into the ES2500 control panel
by cable.
See CH1 Conguraon secon for seng parameters in the control panel.
CONNECTING THE LEVEL SENSOR TO THE CONTROL PANEL
1. Connect power to the controller.
2. Plug the level sensor cable into the sensor mounted to the main tank unit.
3. An NPT thread push tube ng needs to be added to the air inlet port on
the boom of the controller provided by the customer. Air must be supplied
to the air inlet port.
4. The auto-rell controller unit will supply air to the pneumac valve when
the main tank level is low. In that case, the yellow light on the controller will
illuminate indicang the automac rell has been triggered and is currently
lling.
5. Supply air to the inlet on the control box (0-100 PSI max.)
SECTION 5
FLUID DELIVERY CART
Strainer
Fluid Tank
Pump/Motor

17
PROGRAMMING THE LEVEL SENSOR
The tank level sensor comes pre-programmed. However, the set points (Q1 – SP1 and Q1 – RP1) can be adjusted to
congure the system specically for the applicaon.
The level sensor displays the tank level as a percent (%) full. However, all parameters are measured in millimeters
(mm) from the boom of the probe. The usable range of the level sensor is between 10 mm and 410 mm from the
boom of the probe, a 400 mm range.
There are two switching outputs that can be adjusted: Q1 and Q2. Output Q1 is used for the Auto-Rell feature and
output Q2 is used for the Low Tank Level indicator.
To access the above parameters from the main display (% full), press and hold the “Set” buon. Use the up and down
arrows to navigate to “Q1MENU” or “Q2MENU” and press the “Set” buon. Use the up and down arrows to navigate
to “SP1” or “RP1” (or “SP2” and “RP2”) and press the “Set” buon. Use the up and down arrows and the “Set” buon
to change the numeric values assigned to the given parameter. Instrucons for seng other parameters can be found
on pages 32-35 of the provided component manual.
Assuming the tank has been inially lled and given the values in the above table, as the system is being used the level
in the tank will decrease. Once the uid reaches 250 mm from the boom of the probe, 63% full (100% * (250-
10)/380=63%), Auto-Rell will turn on. As the uid level rises and reaches 390 mm from the boom of the probe,
100% full, Auto-Rell will be turned o.
If Auto-Rell is switched o or the supply is interrupted, and the uid level reaches 10 mm from the boom of the
probe, 0% full, the Low Tank Level indicator will turn on. This is intended as a warning that the system is not automa-
cally relling. The Low Tank Level indicator will turn o once the uid level rises above 50 mm from the boom of the
probe, 10% full.
Menu Parameter Name Descripon Preset
Expert Probe Probe Length Length of probe for this applicaon 457 mm
Qa QAHIGH High Level 20ma Maximum tank level (QAHIGH>QALOW) 380 mm
AutCal
Qa QALOW Low Level 4ma Minimum tank level 10 mm
Qa QAPOL Congure Analog output signal as congured QA-Nrm
Qa QATYP Congure Seng the output signal Auto V
DspVal Length Congure Display shows ll level in % %
Q1 SP1 Switching Point 1 High Level - Auto-Rell stops lling 380
Q1 RP1 Reset Point 1 Low Level - Auto-Rell begins lling 76
Q1 OU1 Switching Funcon Output Type - Normally Open/Closed Qx-Hnc
Q2 SP2 Switching Point 2 Not Low Level - Indicator will turn o at or 50
Q2 RP2 Reset Point 2 Low Level - Indicator will turn on at or below 10
Q2 OU2 Switching Funcon Output Type - Normally Open/Closed Qx-Hno

18
6.1 OVERVIEW
In electrostac spraying, a negave charge is introduced into the uid in the manifold body via a central charging elec-
trode. This causes the liquid to become negavely charged, which will then cause the uid molecules to repel each
other.
At the manifold orice, the uid forms into a ny cone. A single stream of droplets will be propelled away from the
orice due to their negave, repelling charge. The droplets will connue to repel each other as they descend, causing
the small droplets to break up into even smaller droplets. This will connue unl the repulsive force between the mol-
ecules is no longer strong enough to break the surface tension and split the droplet.
Yet, these ny and uniformly sized droplets sll retain their negave charge. These uid molecules will be aracted to
any neutral and grounded target nearby through an aracve force stronger than gravity. This electrostac force pulls
the liquid molecules evenly towards the target, coang the surface and providing a very high transfer eciency.
SPECIFICATIONS:
• Width– 6”, 12” or 24” modular secons
• Orice Size– 0.020” (0.51 mm) or 0.030” (0.79 mm)
• Flow Rate (per manifold)- 0.1-20 cc/min per manifold
• System Sizes– 6”, 12” 18”, 24”, 30”, 36”, custom sizes available (combined width, all manifolds)
6.2 MOUNTING
ADJUSTABILITY
The mounng locaon should allow the operator to be able to view the Electrostac Manifold while at the control panel. This will
allow for easier adjustments and ne tuning of the electrostac spray, as the operator will be able to easily see the result of
changing system parameters.
When posioning the uid delivery cart, be aware of its distance from the system control panel mounng locaon—there is a 7-
meter maximum cable run. The uid delivery cart is equipped with caster wheels for easy posional adjustments if needed.
The ES2500 Manifold has been designed to have a high degree of adjustability and can be congured as needed. The
user can control the following:
• The applied voltage
• Fluid ow rate
• The intensity of the electrostac eld
• The height of the Manifold from the target
• Rotaon of the Manifold around its axis for 360-degree coverage
The end mount blocks are pre-drilled with a set of 1/4-20 UNC threaded and 0.266” dia. through holes. These can be
used all together, or in part, to mount the assembly from the top, sides, front, and back.
The more degrees of movement that are built into the mounng scheme, the easier it will be to adjust the spray width
and achieve even uid ow. The nozzle assembly should be able to slide vercally from between 3” to 14” from target
and should be able to rotate from 0 to 90 degrees to the target.
ATTENTION: Nothing metallic or conducve, with excepon to the target, should be within an 18”
envelope of the nozzle. This includes mounng xtures, which should be made of plasc whenever
possible.
SECTION 6
MANIFOLD

19
6.3 HOOK-UP
FLUID LINE
Tubing must be made from a material that is compable with uid to be
sprayed, as well as rigid enough to work with the 1/4” OD tube push-to-
connect ngs that are supplied with nozzle assembly.
ATTENTION: Metallic tubing is not to be used as it will in-
terfere with the electrostac elds and skew the spray or
potenally trip the AccuJet Electrostac Controller. All uid
must be run through a lter capable of removing 90-micron
parculates.
HIGH VOLTAGE CABLE
One side of the nozzle body has an electrode connector like the top of a
spark plug. This plugs into the boot on the high voltage cable. Inside the
rubber boot is a steel fastener. Be sure this fastener is rmly aached to the elec-
trode.
Manifold Fluid Line Connecon

20
GROUND WIRE
The ground wire assembly should come connected to the ground rods with 7/16 hex head bolts on each end of the
conveyor nozzle assembly. The ground wire assembly should be connected directly to an earth ground as dened by
local electrical codes.
6.4 CONTROL FUNCTIONS
VARIABLE ELECTROSTATIC FIELD
The nozzle bodies can be slid up and down inside the end blocks by loosening the 4 plasc thumb screws on both
ends of the assembly. This allows for minor adjustments toward and away from the target, and to increase or de-
crease the eects from the ground rods on the electrostac eld. The ground rods themselves can also be moved in-
ward to increase the eect.
ELECTROSTATIC VOLTAGE
The ES2500 Manifold is rated to work with a voltage from 0-30,000V. This wide range ensures that a variety of uids
will achieve atomizaon and allow for adjustment for spray paern and drop size.
WARNING: DO NOT exceed voltage rang for manifold nozzle assembly; serious injury or death may
occur.
MANIFOLD SECTIONS
Fluid is fed in through the push-to-connect ng directly in the
center of each manifold secon.
The ES2500 Manifold is available in 6”, 12”, and 24” long sec-
ons. These secons can be used individually, or combined, to
create a size that matches the desired spray coverage area.
Examples of possible Manifold conguraons.