AutoJet Sanitary Food Coating Spray System Owner’s Manual

AutoJet VC10 Industrial Heated Spray System

PREFACE

This AutoJet® VC10 Heated Spray Control System and all components are produced and checked at the factory. The system can be dangerous if used incorrectly. Read this manual carefully and read all safety instructions. Operators must always follow the general safety instructions in the working area and aim to prevent accidents. The manufacturer reserves the right to make changes in standard construction without prior notification. Images and diagrams in this manual may not be exact representations of your system configuration.

HOW TO USE THIS MANUAL

• This manual is intended to be a source of information for the operators and technicians who may be installing, interacting with, or servicing/maintaining Spraying Systems Co.® systems and components.
• This manual contains important safety warnings, installation/operating instructions, troubleshooting and maintenance information.

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 instructions are not followed correctly.

ATTENTION : Supplementary information for the user that draws attention to possible problems.

SAFETY

GENERAL SAFETY INFORMATION

READ AND FOLLOW INSTRUCTIONS
All safety-related and operating instructions should be read before the system is operated. Follow all operating instructions.

SERVICING
Do not attempt to service this system unless you have been trained or authorized to conduct repairs. Only authorized and qualified service personnel should attempt to service this system. Service by unauthorized personnel may void any and all warranties.

WARNING : Before performing any maintenance, make sure electrical power is off 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 documentation supplied with the equipment may result in injury to persons or damage to property. Examples of unintended use of equipment would be:

• Using incompatible materials/damaged parts
• Making unauthorized modifications/using unapproved auxiliary equipment
• Removing or bypassing safety guards or interlocks
• Operating equipment in excess of maximum ratings

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 instructions for installation, operation, and service are not followed. All phases of equipment installation 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 potentially hazardous environments and chemicals. This safety equipment includes, but is not limited to, the following:

• Protective 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 recommendations of the Safety Data Sheet (SDS) of any chemical or fluid sprayed using this system.

PRESSURIZED SYSTEMS
It is important to recognize proper safety precautions when using a pressurized spray system. When dealing with pressure applications, the system pressure should never exceed the lowest rated component. Always know your system, all component capabilities, maximum pressures and flow 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 directions.

WARNING OF SHOCK HAZARD

• To reduce the risk of electric shock, do not open the cover on electrical control panel. For service contact Spraying Systems Co.® at 1-866-321-2250.
• Plug panels into a GFCI outlet.
• To prevent injury, avoid contact with potentially 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 pattern.

USE OF CHEMICAL COMPONENTS

The use of any chemicals requires careful control of all worker safety. 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.

INTRODUCTION

The AutoJet® Sanitary Food Coating Spray System is a system that can be used in a variety of applications to properly manage fluid supply of low to mid viscosity fluids. This system consists of a 20-gallon, 316 steel supply tank and sanitary, FDA compliant, air operated diaphragm pump to efficiently deliver processed fluid to the spray nozzles. It offers versatility through a variety of equipment options such as, auto refill for keeping the tank full without disturbing production and in-line liquid heating for viscous spray applications. Sanitary materials and clamp-style connections allow for easy cleaning and low maintenance costs. The recommended Spraying Control Panel options are a separate kit that may not be included.

SPECIFICATIONS

AIR INPUT REQUIREMENTS

• Pressure: 80 psi (min), 100 psi (max)
• Inlet Port: 3/4” SF (f)
• Consumption: Main System: 10 SCFM Normal/40 SCFM Max Operation

ENVIRONMENTAL

• Operating temperature range: 32° to 120°F (0° to 42.8°C)
• Humidity Range: 5 to 95% (non-condensing)

LEVEL SENSOR (OPTIONAL)

• TDR (Time Domain Reflectometry) Level Sensor
  • 4 to 302°F (-20° to 150°C)
  • 232 psi max. (16 bar)
  • 24 V DC

SUPPLY TANK

• 20 gallon (76-liters) tank with removable lid
  • 18” diameter lift-off lid
  • Stainless steel bar leg supports
• Frame mount assembly
  • Stainless steel frame for mounting all components
  • 48 inches long x 36 inches wide x 60 inches high
• 316L SS construction Electropolished

SPRAY CONTROL PANEL OPTIONS

Spray control modules pair with the optional variable spray mount and provides the means to set operating parameters and control the functioning of the automatic spray nozzles. AutoJet® offers three updated panel models to choose from. The controllers are designed to run electric actuated spray nozzles.

50/60, 1Ph., 3A

| 110-240 VAC,

50/60 1 ph., 5A

| 120 VAC, 50/60,

1Ph., 8A

Washdown Closure| ü| ü| ü
Recipes| ü| ü| ü
Trigger Input| ü| ü| ü
Global Compatibility, multi- voltage power cords available| ü| ü| ü
Stainless Steel Control Panel| ü| ü| ü
Power On/Off Switch| ü| ü| ü
Level Switch| ü| ü| ü
Pulse Width Modulation (PWM)| ×| ü| ü
System Outputs| ×| ü| ü
Dual Channel*| ü| ×| ü
HMI Wi-Fi Access| ×| ü| ü
2300 Series Controls| ×| ü| ü
Precision Spray Control| ×| ü| ü
Encoder Input| ×| ×| ü
Flow Monitoring| ×| ×| ü
Pressure Input Sensor| ×| ×| ü
Ethernet IP| ×| ×| ü
High Capacity| ×| ×| ü

OPTIONAL ADD-ONS

These add-on systems are for any liquid delivery supply units.

HD15 IN-LINE HEATER
For applications that require heating the HD15 In-Line Heater is an optional add-on for the Food Coating Supply Unit. The In-Line construction allow heating to be achieved only on-demand for optimal response and energy efficiency. For more information refer the HD-15 In-Line Heater Owner’s Manual.

AUTO-REFILL
Auto-Refill is an optional module that helps refill the supply tank during operation and recirculation. The auto refill system can be added to the Food Coating System and requires a level sensor connection to attach to the control panel. The level sensor displays the current tank level as a percent to full. The refill setpoint can be adjusted for user preference.

TRANSFER PUMP
Easily transfer low to medium viscosity liquids out of drums and totes. Air driven sanitary design, 2:1 ratio piston pump, with air regulator.

FLOW METER
Designed for the 2150+ Spray Control Panel measures the flow of the nozzle

PRESSURE SENSOR
Designed for the 2150+ Spray Control Panel to provide liquid pressure monitoring and application adjustment.

SYSTEM START-UP

Fluid delivery is accomplished via a diaphragm pump mated to a back-pressure regulator allowing for excess fluid pressure to be recirculated back to the supply tank. A manual 2-way valve inlet allows for the option of recirculation of fluid from nozzles back to supply tank. The main air is configured to supply the diaphragm pump with a single connection.

SETUP

Connect all process lines to the tanks, pumps and nozzles. See electrical control panel connections for your specific cables and wiring for your system. Main air is configured to supply the diaphragm pump with a single connection. Before starting the system for the first time, be sure to follow all instructions on the drawings and in the “System Hook-Up and System Operation” section of this manual.

CAUTION : Always check all electrical, hydraulic, and pneumatic connections before powering on the system or turning on air and water supply.

To operate system, follow all startup procedures above.

• To fill the tank manually, open the tank lid and fill to desired level.
• Turn on the air valve to the pump inlet to allow it to start pumping shown in Figure 2.
• Set the desired liquid pressure using the manual pressure regulator shown in Figure 1. Excess pressure/flow will be released through the backpressure regulator and directly back to the tank.
• Adjust the knob on the needle valve to adjust this rate of recirculation allowing for mild agitation of the contents of the tank. Never throttle the valve more than what the nozzles require for operation. This can be checked by running the nozzles and turning down the flow of air to the pump. If you start to see large drops in the air pressure control gauge, the pump speed is too low to keep up. Adjust the needle valve while spraying and circulating to increase pump speed.
• If external circulation to the nozzles and back is desired, an orifice plate is provided at the return.
• Make sure 2-way ball valve on liquid outlet is open and if desired, 2-way ball valve on liquid inlet is open for recirculation.

FLUSH AND DRAIN TANK

• If using auto-refill, complete the steps as needed in the Auto-Refill section of this manual and turn the refill control switch to “ON” (Auto-Refill section in “Optional Add-Ons” section of this
• To empty the tank, either direct the outlet fluid line to a drain or use the spray controller to flush the tank contents through the spray nozzles or header. Fill with any desired cleaning fluid which can be controlled with the approapriate controller. manual).

AUTO-REFILL/LEVEL SENSOR
The automatic refill module allows the refill of the liquid pressure tank without having to shut down the spray process. Auto-refill (optional) comes with a level sensor, pneumatic ball valve, and optional drum pump. The auto refill module accepts a signal from the level sensor that when the liquid is low it triggers the refill tank.
Auto-Refill module consists of:

• Air operated valve control panel
• Continuous liquid level sensor – low level indicator

HOOK-UP AUTO-REFILL AND LEVEL SENSOR TO THE PUMP:

• Connect liquid lines from the pressurized supply to the refill port. Note, the rest position of the refill valve will have a circular indicator to the adjoined ports with no air actuating the valve.
• The re-circulation port, in the rest position, is for recirculating the fluid from the source. This is useful for fluids that fall out of suspension, or if your pump is positive displacement it is required to use this fitting. If you do not wish to re-circulate, please plug this port.
• Next, connect fluid line from the refill valve port to the fill port at the bottom of the tank and connect the air supply to the auto-refill panel.

AUTO-REFILL CONTROL PANEL SET-UP

• Connect power to the controller.
• Plug the level sensor cable into the sensor mounted to the main tank unit.
• The sanitary flange needs to be added to the air inlet port on the bottom of the controller provided by the customer. Air must be supplied to the air inlet port.
• The auto-refill controller unit will supply air to the numatic valve when the main tank level is low. In that case, the yellow light on the controller will illuminate indicating the automatic refill has been triggered and is currently filling.
• Supply air to the inlet on the control box (0-100 PSI max.)

PROGRAMMING THE LEVEL SENSOR

The tank level sensor comes pre-programmed. However, the set points (Q1 – SP1 and Q1 – RP1) can be adjusted to configure the system specifically for the application. The level sensor displays the tank level as a percent (%) full. However, all parameters are measured in millimeters (mm) from the bottom of the probe. The usable range of the level sensor is between 10 mm and 410 mm from the bottom 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-Refill feature and output Q2 is used for the Low Tank Level indicator.

below this value

| 50
Q2| RP2| Reset Point 2| Low Level – Indicator will turn on at or below

this value

| 10
Q2| OU2| Switching Function| Output Type – Normally Open/Closed| Qx-Hno

To access the above parameters from the main display (% full), press and hold the “Set” button. Use the up and down arrows to navigate to “Q1MENU” or “Q2MENU” and press the “Set” button. Use the up and down arrows to navigate to “SP1” or “RP1” (or “SP2” and “RP2”) and press the “Set” button. Use the up and down arrows and the “Set” button to change the numeric values assigned to the given parameter. Instructions for setting other parameters can be found on pages 32-35 of the provided component manual. Assuming the tank has been initially filled and given the values in the above table, as the system is being used the level in the tank will decrease. Once the fluid reaches 250 mm from the bottom of the probe, 63% full (100% * (250- 10)/380=63%), Auto-Refill will turn on. As the fluid level rises and reaches 390 mm from the bottom of the probe, 100% full, Auto-Refill will be turned off. If Auto-Refill is switched off or the supply is interrupted, and the fluid level reaches 10 mm from the bottom of the probe, 0% full, the Low Tank Level indicator will turn on. This is intended as a warning that the system is not automatically refilling. The Low Tank Level indicator will turn off once the fluid level rises above 50 mm from the bottom of the probe, 10% full.

TRANSFER PUMP

Easily transfer low to medium viscosity liquids out of drums and totes. air driven, 2:1 ratio piston pump, with air regulator.

SPECIFICATIONS

• Max. Air Inlet: 100 PSI (6.89 Bar)
• Max. Fluid Working Pressure: 250 PSI (17.24 Bar)
• Max. Output Flow: 2.5 GPM (9.46 Ipm)
• Air Consumption:10.5 SCFM
• Max. Fluid Temp: 180°F (82°C)

SYSTEM START-UP

• Check the regulator reads “0” psi.
• Make sure all air and liquid supply fittings/lines are connected and secured fully before starting.
• Start transfer pump process by turning the knob on the filter/regulator clockwise.
• Slowly raise air pressure until the transfer pump begins cycling.
• Use the regulator to control the pump speed and liquid pressure.
• Since this is a 2:1 ratio piston pump, a pressure reading on the filter/regulator of 40 psi will output 80 psi.

PRESSURE RELIEF PROCEDURE

• Using the filter/regulator, turn knob counterclockwise to relieve pressure.
• Once gauge reads “0” psi, the liquid supply can be removed.
• If nozzle/hose is clogged/pressure has not been fully relieved after following the steps above, very slowly loosen the hose end coupling to relieve pressure gradually, then loosen completely. Clear hose or nozzle blockage.

CAUTION : Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.

WARNING : Never let the pump run dry of the fluid being pumped. A dry pump can accelerate and cause personal injury and/or damage to the pump.

FLUSHING

• Flush at the lowest possible pressure and flush with a fluid that is compatible with the fluid being dispensed and the equipment wetted parts.
• After Pressure Relief Procedures above, place suction tube in drum containing flushing fluid.
• Set pump to lowest fluid pressure, and start pump.
• Cycle pump until desired flushing is complete.
• Completely relieve air pressure to pump before removing pump from drum.

PRESSURE SENSOR

IF YOU HAVE PRESSURE SENSOR:
Hook-up the 3/4” SF (f) outlet to the 3/4” SF (f) liquid outlet on the pump. Than attach the M12 pressure port cable to the corresponding M12 solenoid cable for cylinder air port on the ACP. See your specified Control Panel Manual for all sensor and cable specifications.

SPECIFICATIONS

General

• Measuring range: 0-100 psi (7 bar)
• Cable details: M12 (M) – 5 m
• Protection rating (all sensors): IP67/IP69K

Standard, Flush-Style Diaphragm, and Sanitary pressure sensors are available

• The flush-style diaphragm pressure sensor is used with fluids that contain solids.
• The sanitary pressure sensor is used with any sanitary configurations (if applicable).

Liquid Connections – Connection Types

• Threaded: 3/4″ SF (male x female)
• Sanitary: 3/4″ tri-clamp flange (Inlet/Outlet)

FLOW METER

SINGLE AND DUAL CHANNEL ADD ON

The SCS Series flow meter is mounted on a plate. With a single channel 2150+, you will receive the standard single channel flow meter. If you have a dual channel 2150+, you will receive the standard single channel flow meter with a second channel add-on.

• Flow meters are pre-programmed, but still require origin and span adjustments.
• For detailed flow meter setup instructions, refer to the flow meter manual provided with the system.

ORIGIN ADJUSTMENT

While the pipe section with the flow meter is filled with fluid and fluid is not moving, press and hold the up and down directional buttons until the origin adjustment screen appears. Use these buttons to select “yes” and then press the mode button and wait while the settings are saved.

SPAN ADJUSTMENT

Span adjust is initially set for water and will need to be adjusted to suit your process fluid. To do this, navigate to the span adjust setting under advanced settings after setting flow tuning to span adjust. Then perform test sprays for a set time and record the mass of fluid sprayed and the volume of fluid reported to the spray control panel. Adjust the span up or down to reflect this measured spray and conform with further test sprays.

• Clamp-on style flow meter
• Overall dimensions: 18″ x 12″ x 5.5″
• Mounting dimensions: 17″ x 11″ – 0.34″ dia. holes
• Ambient temperature: 14-140°F (-10-60°C)

Fluid Connections:

• Threaded version: 1/2″ NTP (F) Inlet/Outlet

Flow Rate:

• Maximum: 5.28 GPM (20 L/min)
• Minimum: 0.02 GPM (0.076 L/min)

CLEANING/MAINTENANCE.

ATTENTION: Cleaning procedure is only a suggestion. Customer is ultimately responsible for a sanitation procedure that meets their requirements and standards.

CLEANING PROCEDURE

• Turn the auto-refill switch on the main control panel to the “OFF” position (if applicable).
• Close the 2-way ball valve on the pump’s incoming air inlet port. This stops the pump from operating.
• Close the recirculation port 2-way ball valve.
• Remove the hose/ tube connecting to the recirculation port inlet and use this line to remove majority of the fluid in the tank.
• When ready, open ball valve for air inlet to the pump again to start draining the tank and fluid lines.
• Once the tank is empty, then majority of the fluid is drained. Reconnect the open hose/ tube to the recirculation port and open the recirculation ball valve.
• At this point, the end user can fill the tank with their recommended cleaning solution. The cleaning solution can be recirculated.
• Use the control panel to spray the nozzles until all process fluid remaining in the hoses, manifolds and nozzles is discharged.
• Clean the auto-refill system (as applicable).
  • Liquids for cleaning, rinsing, and sanitation can be added to the auto-refill supply tank and fluid de livery line.
  • Turn the auto-refill switch to the “ON” position to begin filling.
  • When complete, turn the auto-refill switch to the “OFF” position to stop pumping.
  • Repeat this process with appropriate fluids till the system is thoroughly flushed.
• Clean the tank, delivery hose and nozzle assemblies.
  • Liquids for cleaning, rinsing, and sanitation can be added through the open top of the tank or fed through the auto-refill system.
  • Any inside surface on the pressure tank, sensors, or dip tubes can be manually cleaned, scrubbed, or wiped down.
  • Use the control panel to spray and move cleaning and sanitizing fluids through the hoses, manifolds and nozzles.
• The fluids, time to flush, repetitions, etc.… are to be determined by the end user to meet your required level of cleaning and sanitation.
• After cleaning and sanitation, return all valves and port covers to their production ready state.

MAINTENANCE

ATTENTION : Any long term shut-down requires that all liquid lines, liquid components, pumps, spray guns be flushed and cleaned thoroughly.

·         Check system main air

pressure as specified

| ·         Tighten all screw terminal connec- tions to insure proper bonding.| ·         Check component calibration and re-calibrate if required.

See individual control

component manuals for calibration procedures.

Liquid Controls| N/A| ·         Check all liquid connections, in-

line filters, tubes/

hoses for leaks.

| N/A| N/A
Spray Nozzles| ·         Check all spray guns for leaks or mechanical mal- functions| ·         Clean, lubricate, and adjust all spray guns.| N/A| N/A

TROUBLESHOOTING

Please refer to troubleshooting below or contact Spraying Systems Co. for further assistance. System does not spray or has a bad pattern

• Check air supply pressure on pump
• Check ball valve at the fluid outlet and inlet if recirculating
• Power to the Control Panel
• Check wiring between the Control Panel and the PulsaJet gun(s)
• Verify Trigger signal
• Check nozzle for clogging.

Air in liquid line/Poor pump performance

• Check pump air supply and regulator
• Check for leaks in air inlets
• Check for leaks in liquid inlets
• Disassemble pump and check for damaged diaphragm or seals

SPARE AND REPLACEMENT PARTS

Flow Meter

Part| Part Number
Cable Glands, Strain Reliefs & Cord Grips LTCG 3/4 NPT 8.5mm SPLIT BLACK| CG00836M3234GBH
Flow Sensor Controller: Main Unit, DIN Mount for FD-X series| FL00FD00XA1
Clamp, Metal Pipe, 10.8mm – 14mm, 1/2″ ODT, for use w/ FD-XS20| FL00FDXC20M2
Flowmeter, Ultrasonic, Sensor Head, 0 – 20000 mL/min, clamp on, 2m cable, used w/ FDX controller & FDX clamp| FL00FDXS20
Five-meter cable, M12 (f), M12 (m), 4 wire| LEXXSD4FD4M005P
Standard Key Connector, 4-Wire M12 (m), 18 ga. max., 4A, Field Wire-able| JC00BS81410
Part| Part Number
---|---
Pump Diaphragm, NDP-20 series, 3/4” NPT, 316 SS Body, PTFE Diaphragm| PU00ND20BST
Sensor, level, TDR (Time Domain Reflectometry), analog 4-20 ma, 2 switching outputs (1 pnp, 2 npn/pnp), 12-30 VDC, 1000mm length (can be cut as low as 200mm)| LS00FP1000G1NMB
Food Coating, Sanitary, 3/4″ Quick-Clamp Fluid Connections, Main Assembly| 240TS24000143W0
20 gallon Tank replacement, 18” lift off lid| 240TS24000191W0
100 mesh size strainer (1/2TWD-FC100)| 240TS24000134W0
Needle valve for recirculation kit| 240TS24000139W0
Pressure Sensor| Parts Number
---|---
Clamp, 1/2” to 3/4” sanitary tri-clamp, 316SS| CL004750K61
Clamp, 1” to 1.5” sanitary tri-clamp, 316SS| CL004759K62
Gasket, 1/2” sanitary tri-clamp Viton| FRMM5044K11
Gasket, 1.5” sanitary tri-clamp, Viton| FRMM5044K14
Cable, M12 (f), M12 (m), 5 meter| LEXXSD4FD4M005P
Adapter, G1/Vario fitting to 1.5” tri-clamp, 316 SS, Use with PR00PG2795| PL00E33208
Fitting, tee, sanitary, instrumental, 3/4” x 1.5” tri-clamp, short, 316LSS| PL00TEG7R6L1575
Pressure Transmitter, -14.5…145 psi range, 4 wire DC, 4-20mA scalable analog and PNP.NPN| PR00P12794

© 2022 All rights reserved. Printed in the U.S.A.
Under copyright laws, this manual may not be reproduced in any form, in whole, or in part, without prior written permission from Spraying Systems Co® . This revision supersedes all previous revisions. Every effort has been made to ensure that the information in this manual is accurate at the time of printing. However, Spraying Systems Co. assumes no liability for errors or omissions and reserves the right to make changes without notice to any products described herein to improve reliability, function, or design. Other company and product names may be trademarks of their respective companies. Warranty is one (1) year on non-wear parts from ship date. Wear items are covered for manufacturing defect only for a period of one (1) year. Wear items include, but may not be limited to, Liquid pump and Liquid regulator. Seller warrants that its products will conform to and perform in accordance with the products’ specifications. Seller warrants that the products do not infringe upon any copyright, patent, or trademark. THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THOSE CONCERNING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Spraying Systems Co.

North Avenue and Schmale Road, P.0. Box 7900, Wheaton, IL 60187-7901 USA

• Tel: 1.800.95.SPRAY
• Fax: 1.888.95.SPRAY
• www.spray.com
• Intl. Tel: 1.630.665.5000
• Intl. Fax: 1.630.260.0842

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