What should my initial system setting be?
There are several different adjustments that can be made on most Unist spray systems to fine-tune the performance for a given operation. There are many different factors in any operation that can affect the output that is required from the system. The information below is meant to create a starting point from which adjustments can be made to dial the system in to achieve optimum performance. The related video also gives some helpful initial setup information.
The three main settings that can be easily modified on Unist spray systems are pump cycle rate, atomizing air flow, and pump stroke.
- Pump Cycle Rate: The pump cycle rate is recommended as the primary adjustment to either increase or decrease fluid output from the system. On a Coolubricator™ the pump cycle rate is controlled by an adjustable pulse generator. The pulse generator (PG) is factory set to 10 pulses/min. Depending on the application, the recommended range is between 5-50 pulses/min with a max of 200 cycles/min (although this rate is not recommended for continuous operation). On Quantum™and Revolution™systems that pump cycle rate is controlled electronically as denoted on the display in either drops per minute or volume per unit time (e.g. mL/min or oz/hr). The Serv-O-Spray™system operates somewhat differently and only cycles the pump once each time that a signal (air pilot, electrical, or manual) is sent to the system. On a Coolubricator™, Quantum, and Revolution™ systems a good starting point for the pump cycle rate is 10-20 cycles per minute.
- Atomizing Air Flow: On systems that use a metering screw to control the atomizing air flow at the nozzle, a good initial setting is ¾ of a turn out from fully closed. Many different factors including hose length, nozzle type, fluid viscosity, and application type can affect the optimum air metering screw setting. Generally, there only needs to be enough air flow to properly atomize and push the fluid onto the tool or workpiece. Too little air flow may not properly atomize the fluid and lead to large fluid droplets and inconsistent output. Too much air flow can cause excessive fogging and waste of compressed air. Most customers have obtained excellent spray results by opening the air metering ½ to ¾ of a turn from fully closed. Minute adjustments can be made from there until proper operation has been achieved.
On Quantum™and Revolution™systems that utilize proportional air control (all Revolutions and some Quantums) the air flow setting is a unitless number that controls a proportional air flow valve. On a Revolution™that number is adjustable from 0-65. A good starting value is 25-35. On Quantum™systems, the number is adjustable from 0-100. A good starting value on those systems is 50-60.
- Pump Stroke: Pumps come from the factory set at full stroke. The stroke can be reduced to tune a system to get optimum and consistent fluid output for a specific application. For instance, if a Coolubricator™ set at 10 cycles per minute at full stroke does not give good consistent fluid output, the cycle rate can be increased to 20 cycles per minute. The pump stroke can be adjusted to half to achieve the same average fluid output, but yield a more consistent output. On a standard pump, the stroke is increased when the brass adjustment knob is turned clockwise and reduced when the adjustment knob is turned counterclockwise. On an MV pump the stroke is decreased when the black aluminum adjustment knob is turned clockwise and increased when the adjustment knob is turned counterclockwise. It is normally best to keep the stroke adjustment between full and half stroke for optimum and consistent output.