Spraying Systems 63600 PulsaJet Manifold Owner’s Manual

: October 27, 2023
: Spraying Systems

Table of Contents

PREFACE
- IMPORTANT
- HOW TO USE THIS MANUAL
SAFETY
- GENERAL SAFETY INFORMATION
- UNPACKING THE SYSTEM
MANIFOLD COMPONENTS
MANIFOLD TEST PROCEDURES
- PERFORMING DECAY TESTING
ALTERNATIVE 63600-PJ KIT NUMBERS
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

AutoJet® 63600 PulsaJet® Manifold
OWNER’S MANUAL

SECTION 1

PREFACE

IMPORTANT

This AutoJet® 63600 PulsaJet® Manifold and all components are produced, tested 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/or 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, and troubleshooting/ 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.

SECTION 2

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 will void any warranties.

WARNING: Before performing any maintenance, make sure electrical power is off and that any air and 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 operation, electrical and pneumatic safety. The use of any unauthorized replacement parts will void any warranties.

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:

Using incompatible materials
Making unauthorized modifications
Removing or bypassing safety guards or interlocks
Using incompatible or damaged parts
Using unapproved auxiliary equipment
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 or safety gloves and apron
Long sleeve shirt and long pants Users of this product should never place themselves in the path of the resulting 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.
WARNING: Plug panels into a GFCI outlet.
WARNING: 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 in the spray pattern.

UNPACKING THE SYSTEM

The system components come carefully packaged to protect them from damage. Use caution 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 installation and connection.

CAUTION: The packaging may contain exposed cables, hoses, or other components. Always exercise caution when opening boxes to avoid accidental damage or slicing of various components.

SECTION 3

MANIFOLD COMPONENTS

63600-PJ COMPONENTS

Manifold body: The manifold body surrounds the nozzle body and provides the jacketing and cleanability.
Nozzle body: The nozzle body contains all the internal nozzle components for spraying.
End plate: All fluid and electrical connections pass through the end plate into the manifold. The connections will change depending on the features of the 63600. Such as: if the fluid is recirculating or not or if zoned or non-zoned nozzles are used.
Electrical connection: The electrical connection is either an M12 whip (shown above), or an M23 bulkhead. Generally, the M12 whip is used for non-zoned manifolds and the M23 bulkhead is for zoned manifolds.

DISASSEMBLING NOZZLE BODY

When disassembling the nozzle body for maintenance, it is important to make sure that a good seal is formed between the O-rings on the coil and the body of the manifold. If the coil is removed, a decay test must be performed as described in section 4.
If inspecting or replacing the nozzle tip, plunger, or spring, the coil does not need to be removed. Remove screws “A” and “C”, then remove the cover plate (Item 5 in the parts list), to access the plunger and spring.
If the coil itself or the O-rings on the coil need to be inspected or replaced, the nozzle body can be further disassembled by removing screws “B” and “D” and removing the second cover. The coil can then be accessed as seen in Figure 4. When reassembling, take care to ensure the wires connected to the coil are fed down the conduit tube and do not become folded or bunched such as they are damaged, or that the coil O-ring cannot seal against the manifold.

NOZZLE REBUILD KITS

All parts listed below, except the nozzle tip, can be ordered as a kit. Part quantities listed are per nozzle body.

NOZZLE REBUILD KIT – 63600-PWNDKIT-03-EPRFDA

| Item| Description| Qty.
1| Retaining cap| 1
2| Coil sub-assembly FDA| 1
3| Spring .240 od x .016 wird dia.| 1
4| Plunger sub-assembly| 1
5| Dovetail cover plate| 1
6| Cover Plate| 1
7| Screw, hex head, #6-32 x 1/2” long, ss| 4
8| O-ring, 2-103, FDA epr.| 3
9| O-ring, FDA epr.| 1
10| O-ring, m29 x 1.5, FDA epr.| 1
11| Nozzle tip| 4

| NOZZLE REBUILD KIT| 63600-TPUKIT-03-_
---|---|---
Item| Description| Part No.
1| Plunger| 50697-1
2| Retainer Cap| CP1325-SS
3| O-Ring| CP7717-2/13-
4| O-Ring| CP7717-4-
5| O-Ring| CP7717-7-
6| O-Ring| CP7717-M29X1.5-
7| Coil| CP50685
8| Spring| CP50691-SS
9| Hex-head screw, #6-32 x
1/2” Long| CP55001-76-SS
10| Seat Insert| CP55044-316SS
11| Cover Plate| CP114312-18FMS
12| 2-position housing connector| JC00EHR2
13| Socket ferrule| JC00SEH001TP06

| NOZZLE REBUILD KIT| 63600-PWMDKIT-03-_
---|---|---
Item| Description| Part No.
1| Plunger| 50697-1
2| O-Ring| CP7717-2/13-
3| O-Ring| CP7717-4-
4| O-Ring| CP7717-M29X1.5-__
5| Coil| CP50685
6| Spring| CP50691-SS
7| Hex-head screw, #6-32 x 1/2” Long| CP55001-76-SS
8| Retaining Cap| CP104218-316SS
9| Dovetail Cover plate – 5° offset angle| CP114723-1-5-316SS
10| Inlet Cover body| CP114724-1-18FM
11| 2-position housing connector| JC00EHR2
12| Socket ferrule| JC00SEH001TP06

MANIFOLD END PLATES

When disconnecting manifold, secure tethered cap to the electrical connection to prevent water from getting inside.

NON-ZONED CONTROL ELECTRICAL SIGNAL

ZONED ELECTRICAL SIGNAL

SECTION 4

MANIFOLD TEST PROCEDURES

PERFORMING DECAY TESTING

REQUIRED MATERIALS

Decay testing jig
Shop air that provides at least 60 psi
63600 manifold

PRELIMINARY PROCESS
The process owner will confirm that the decay testing jig has no leaks.

Clamp a cap to the outlet side of the jig.
Apply ≤50 psi shop air.
Close the 2-way valve.
Disconnect the shop air.
Hold the pressure, and wait 5-10 minutes to confirm that there is no loss of pressure in the jig.
If there is a leak, retighten the fittings or take the fittings apart and apply new seal tape. Retest the jig by repeating steps 1 – 5.

DECAY TESTING PROCESS

Connect the jig to the manifold with the ½” Tri-clamp and gasket.
Make sure that the jig valve is closed.
Connect shop air line to the air input side of the jig.
Open the valve on the jig.
Once the valve has been opened, apply 50-55 psi of air pressure.
When the gauge settles, slowly shut the valve.
NOTE : The exact value for air pressure applied is not important once it is within the specified range, however, it is important to note the starting pressure value so that any changes can be observed.
Record the gauge value. Observe and record gauge pressure again after a waiting period of 30 minutes. A loss of 12 psi may be gage settling. Confirm that the value does not change prior to the waiting period.
If, after 30 minutes, there is no more than a loss of 0.5 psi, the 63600 manifold passes.

Decay Testing Jig
P/N: 500TS50020048A0

SECTION 5

ALTERNATIVE 63600-PJ KIT NUMBERS

Kit No.	Description
63600-PWMDKIT-03-EPRFDA	PWMD dovetail-style tip adapter and uses EPR – FDA

O-rings
63600-PWMDKIT-03-VIFDA| PWMD dovetail-style tip adapter and uses Viton – FDA O-rings
63600-TPUKIT-03-EPRFDA| TPU standard tip adapter and uses EPR – FDA O-rings
63600-TPUKIT-03-VIFDA| TPU standard tip adapter and uses Viton – FDA O-rings

© 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.

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

Tel: 1.800.95.SPRAY
Fax: 1.888.95.SPRAY| Intl. Tel: 1.630.665.5000
Intl. Fax: 1.630.260.0842
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MLO063600-P) Rev. 3 8/2022