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ProfiTech M

P_02191

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC 2335144

MCM cable set 10 m; 32.8 ft:

Order No. 2330002

Cable set for connection of master module and 
controller module

Consists of:

MCM CAN BUS connection cable 10 m

Order No. 2330005

2330005

MCM connection cable 16-pin 10 m

Order No. 2330006

2330006

MCM connection cable 4-pin 10 m

Order No. 2330007

2330007

CAN bus extension cable

CAN bus cable M12 plug / coupling PVC 0.6 m

Order No. 2320127

CAN bus cable M12 plug / coupling PVC 2 m

Order No. 2320128

CAN bus cable M12 plug / coupling PVC 5 m

Order No. 2320129

CAN bus cable M12 plug / coupling PVC 10 m

Order No. 2320130

CAN bus cable M12 plug / coupling PUR 15 m

Order No. 2328556

CAN bus cable M12 plug / coupling PUR 20 m

Order No. 2328557

Summary of Contents for ProfiTech M

Page 1: ...II 3D Ex tc IIIB T60 C Dc ProfiTech M Hardware Installation Version 07 2014 Translation of the Original Operating Manual...

Page 2: ......

Page 3: ...tructions for the Operator 13 4 1 1 Electrical Devices and Equipment 13 4 1 2 Staff Qualifications 13 4 1 3 Safe Work Environment 13 4 2 Safety Instructions for Staff 14 4 2 1 Safe Handling of WAGNER...

Page 4: ...ncoder 50 7 8 Connections in the Rack 51 7 9 Connecting the Automatic Spray Guns on the EPG S2 52 7 10 Connecting the Manual Guns to the EPG Sprint X 53 7 10 1 Signals on the EPG Sprint X 54 7 10 2 Pa...

Page 5: ...f 89 9 1 2 Safety Instructions 89 9 1 3 Cleaning Procedures 90 9 2 Maintenance 91 9 2 1 Maintenance Staff 91 9 2 2 Safety Instructions 91 9 2 3 Safety Checks 92 9 2 3 1 Grounding Check 92 9 2 4 Mainte...

Page 6: ...ger and its consequences DANGER This notice warns you of a hazard Possible consequences of not observing the warning instructions The signal word indicates the hazard level The measures for preventing...

Page 7: ...ech M system 1 3 LANGUAGES The operating manual is available in the following languages German 2335143 English 2335144 French 2335145 Italian 2335146 Spanish 2335147 Russian 2350911 1 4 ABBREVIATIONS...

Page 8: ...her the potential risks associated with improper behavior as well as the necessary protective devices and measures Electrician Can assess the work assigned to him her and detect possible hazards base...

Page 9: ...t protection caps WAGNER accepts no liability for any damage arising from non intended use Use the device only to work with the products recommended by WAGNER Operate only the device as a whole Do not...

Page 10: ...Wear protective clothing Operation allergies observe safety data sheets maintenance disassembly Powder lacquer in air outside the defined working area Lacquering outside the defined working area Inha...

Page 11: ...Symbol for explosion protection II Device class II 3 Category 3 D Ex atmosphere dust tc Protection provided by housing device protection level according to DIN EN 60079 31 IIIB Maximum surface temper...

Page 12: ...in fuse MCM CPS I O Control 230 400VAC 50 60Hz max 5 1kW 35A Baujahr Year of manufactur J Wagner AG CH 9450 Altst tten Made in Switzerland II 3D F r den Betrieb in Zone 22 m ssen alle Kabeleinf hrunge...

Page 13: ...the device is operated maintained and repaired only by trained persons The floor in the working area must be electrostatically conductive measurements according to EN 1081 and EN 61340 4 1 The footwea...

Page 14: ...uctive shoes The functionality of grounding cables must be checked regularly see EN 60204 Alwaysfollowtheinformationinthismanual particularlythegeneralsafetyinstructions and the warning instructions A...

Page 15: ...n and locked to prevent it from being switched back on Lock the compressed air supply and decompress the device Secure the device against being switched back on without authorization Use only electric...

Page 16: ...m 3 94 inches The label plates which must be attached are shown below High voltage In the control cabinet 25 mm 0 98 inch voltage before main switch Forbidden for unauthorized persons Explosive atmosp...

Page 17: ...arranty liability and guarantee claims by the manufacturer 5 DISCLAIMER 5 1 HARDWARE 5 2 SOFTWARE The production of software copies intended for sale or installation in the end user s proprietary syst...

Page 18: ...MCM Master Control 1 2330001 MCM CPS I O Control 1 2330002 MCM cable set 10 m The standard equipment includes 1 2335279 Declaration of Conformity 1 2335143 Operating manual German 1 see Chapter 1 3 Op...

Page 19: ...Control Module Order No 2330000 The MCM Master Control Module serves as an operating unit and as a controller MCM CPS I O Control Module Order No 2330001 The Control Module serves as supply and input...

Page 20: ...n cable 16 pin 10 m Order No 2330006 2330006 MCM connection cable 4 pin 10 m Order No 2330007 2330007 CAN bus extension cable CAN bus cable M12 plug coupling PVC 0 6 m Order No 2320127 CAN bus cable M...

Page 21: ...2192 P_02193 OPERATING MANUAL VERSION 07 2014 ORDER NUMBER DOC 2335144 CAN bus termination Order No 2321402 for EPG S2 and external extension CAN bus termination Order No 2338042 for light curtain and...

Page 22: ...rsal control unit for Corona or Tribo powder spray guns or field controller One EPG S2 can control two spray guns A maximum of 16 EPG S2 double modules can be connected to an MCM system maximum 32 aut...

Page 23: ...n set EPG S2 Order No 2321529 CAN bus cable 0 6 m 1 97 ft Order No 2320127 Mains cable 0 55 m 1 80 ft Order No 241269 Grounding cable Order No 360254 Hose 6 8 mm 0 32 inch black Order No 9982078 Hose...

Page 24: ...No 2321402 Hose 4 6 mm Order No 9982079 Hose connection between EPG S2 EPG Sprint X and spray gun Hose 6 8 mm red Order No 9982063 Feed air hose from EPG S2 EPG Sprint X to powder injector Hose 6 8 m...

Page 25: ...RDER NUMBER DOC 2335144 6 6 PULSE GENERATOR COMPONENTS Encoder Order No 2335582 Hollow shaft encoder 24V 100 pulses Bracket set for encoder Order No 2335512 Connection cable for encoder Order No 23365...

Page 26: ...NENTS Kontur 2 light curtain resolution 10 40 mm Order No Order No Length mm inch Resolution 20 mm Resolution 40 mm 320 12 60 3158584 3127544 480 18 90 3158585 3127327 640 25 20 3158586 3127549 960 37...

Page 27: ...ech M OPERATING MANUAL VERSION 07 2014 ORDER NUMBER DOC 2335144 Quattro CAN open control unit for light curtain Order No 2330630 Power supply cable to Kontur 2 light curtain Per meter 3x1 0 mm Order N...

Page 28: ...T 1 910 mm 20 mm 2345158 CML720i 2230 20 S T 2 230 mm 20 mm 2345159 CML720i 2550 20 S T 2 550 mm 20 mm 2345160 CML720i 2870 20 S T 2 870 mm 20 mm 2345161 CML720i 610 40 S T 610 mm 40 mm 2345162 CML72...

Page 29: ...light curtains are used Connection cable for 24 VDC Order No 2329743 Length 25 m This cable is used for the voltage supply if just one light curtain is used e g height light curtain 24 VDC field dist...

Page 30: ...for positioning a reciprocator in automatic powder coating systems The number after the HU1 designation specifies the maximum displacement in mm HU1 600 sliding table Order No 2327619 HU1 1000 slidin...

Page 31: ...he following small components pictured are not lost Small components For the assembly of the mechanical components and to connect electric cables and the like System dependent consisting of screws nut...

Page 32: ...on CF type 2 Software CE6 CoDeSys VisiWin net Interfaces Ethernet 2 x CAN open Master USB 2 0 Real time clock Battery back up 3 V lithium button cell CR 2032 Operation EMERGENCY STOP main switch illu...

Page 33: ...1 5 kW Protection class IP 54 if not used connections are closed Power supply unit 24 VDC 5A 120 W Output 1 2 motion groups F3A and F4A per C25 A control system Output 2 2 EPG S2 Groups F2A and F2B pe...

Page 34: ...units 3 x light curtains 3 light curtain portals with Kontur 2 with Quattro CAN Open 4 x light curtains CML 720 light curtains 3 times for the portal 1 time for code catching 11 x digital inputs Digit...

Page 35: ...maximum 22 Vpp Output current 2x maximum 0 9 A High voltage 2x 10 100 kV adjustable in 1 kV steps Corona current limitation 5 A 120 A adjustable in 1 A steps Tribo current measurement 0 A 5 A resolut...

Page 36: ...kV steps Corona current limitation 5 A 120 A adjustable in 1 A steps Tribo current measurement 0 A 5 A resolution 0 5 A Tribo current limitation 0 A 5 A adjustable in 0 1 A steps Tribo current cut off...

Page 37: ...norm cubic meter HINT Compressed air quality accessories Danger of damage to the device Operate the control unit only with the prescribed compressed air quality Only use the control unit with origina...

Page 38: ...op button 3 Display Fault Lights up red in the event of a malfunction Fault acknowledgement and safety relay start button 4 ON OFF switch for the PC controller and EPG S2 5 System release display Ligh...

Page 39: ...ion LED flashes lights up green during the data communication with the master 3 LED display Release The LED lights up green when enabling has taken place 4 LED display Air The LED lights up green when...

Page 40: ...tored in a dry location free from vibrations and with a minimum of dust The control components gun must be stored in closed rooms The air temperature at the storage location must be between 5 C and 45...

Page 41: ...ement Enter the parameters in the MCM 11 Set the VU reciprocators mechanical stops and measure the resulting maximum stroke Enter the parameters in the MCM 12 Move the HU reciprocator and lifting slid...

Page 42: ...2014 ORDER NUMBER DOC 2335144 7 5 SETTING UP THE RACK Fastening holes Danger of tipping Risk of injury and damage to the device Secure the rack against tipping during transport Screw rack to base at t...

Page 43: ...or the secure separation of the motion technique s power supply 6 Circuit breaker for motion EGP S2 and control system 7 Push in connector for 4 CAN buses 2 EPG Sprint Xs and 1 conveyor encoder 8 X10...

Page 44: ...hannel 2 X12 3 and 4 Potential free NCC X13 terminal block for conveyor technology and system OK Function Signal Terminal strip Clamps Contact Signal type Safety switching device external Channel 1 ON...

Page 45: ...6 Digital output 24 VDC 100 mA GND for inputs and outputs GND X20 17 GND X21 terminal block for booth control cabinet Function Signal Terminal strip Clamps Contact Signal type Fire alarm Channel 1 X21...

Page 46: ...on group 2 AC 230 VAC X30 8 Phase fuse C25A F3B Motion group 2 AC Neutral X30 9 Neutral conductor Motion group 2 AC Earth X30 10 Grounding connection EPG group 1 AC Earth X30 11 Grounding connection E...

Page 47: ...4 EPG S2 No 4 Guns 7 and 8 35 EPG S2 No 5 Guns 9 and 10 36 EPG S2 No 6 Guns 11 and 12 37 EPG S2 No 7 Guns 13 and 14 38 EPG S2 No 8 Guns 15 and 16 39 EPG S2 No 9 Guns 17 and 18 40 EPG S2 No 10 Guns 19...

Page 48: ...Tech M OPERATING MANUAL VERSION 07 2014 ORDER NUMBER DOC 2335144 7 7 CONNECTING THE MCM MODULE MCM Master Control Order No 2330000 MCM CPS I O Control Order No 2330001 Cable set 10 m 32 81 ft Order No...

Page 49: ...OPERATING MANUAL VERSION 07 2014 ORDER NUMBER DOC 2335144 7 7 1 CONNECTIONS ON THE MCM MASTER CONTROL 24 VDC CAN bus Signals 16 pin Cable entry 7 7 2 CONNECTIONS ON THE MCM CPS I O CONTROL 24 VDC CAN...

Page 50: ...ntry on the MCM CPS I O Control For tailored cables with plugs use separated cable entries 3x cable set 4x CAN bus cable 2x EPG Sprint X 1x conveyor encoder Close holes which are not used 7 7 3 CONNEC...

Page 51: ...9 7 10 Connection cables see Chapters 6 4 6 11 Connect ground wire to EPG S2 and to signal ground Connect supply voltage cable Order No 360263 to the clamp strip E2 X2 in the control cabinet Connect c...

Page 52: ...ON THE EPG S2 Tribo spray gun Corona spray gun Mains input terminal Signal ground e g from the powder tank Powder injector Mains output to next control unit Atomizing air A Y distributor is needed to...

Page 53: ...ns input terminal Grounding cable to the signal ground e g from the powder tank Compressed air main supply 0 6 0 8 MPa 6 8bar 87 116 psi Hose diameter 8 mm 0 315 inches Powder injector Dosing air blue...

Page 54: ...5605 This cable can also be used to lengthen an identical cable in 10m 32 81 ft increments 7 10 2 PARAMETER SETTING ON THE EPG SPRINT X For the control of the manual guns the C26 parameter Operating m...

Page 55: ...ly 230VAC for the EPG S2 takes place via the X30 clamps 11 13 EPG 1 and X30 14 16 EPG 2 The same clamps can be used for the supply of the EPG Sprint X A maximum of 10 EPG control units can be connecte...

Page 56: ...L VERSION 07 2014 ORDER NUMBER DOC 2335144 7 12 CONNECTING THE CONVEYOR ENCODER A 100 pulse quadrature encoder Order No 2335582 is used and connected via an encoder cable Order No 2336565 If necessary...

Page 57: ...KONTUR 2 LIGHT CURTAINS Connection cables Kontur 2 Length system dependent Light curtain Kontur 2 Length system dependent Connect supply voltage cable Order No 3052605 to the terminal strip X10 1 24...

Page 58: ...cted on connection M12 LC in the MCM CPS CAN bus cables with a length of 5 m 16 40 ft 10 m 32 81 ft or 20 m 65 62 ft can be used Cable coupling M12 LC Terminal X10 1 24 VDC wire 1 Terminal X10 3 GND w...

Page 59: ...ion First switch off 24 VDC supply or remove connection box at Quattro control section 2 A brass ring can be found at the connection thread of every light curtain This ring finishes level with the fas...

Page 60: ...ng cable from the ground terminal on the Quattro control section to the equipotential bonding strip 7 As the portal profiles are made of anodized aluminum grounding via sliding blocks is insufficient...

Page 61: ...014 ORDER NUMBER DOC 2335144 7 13 3 CONNECTION DIAGRAM FOR LGS LIGHT GRID Receiver 8 Pin Sender 4 Pin white green yellow brown blue Control cabinet wiring diagram Sender 24 V brown X10 1 0 V blue X10...

Page 62: ...sunlight This can be achieved with sufficient spacing appropriate positioning or partitioning 1 Select the type of fastening for transmitter and receiver Fastening using T groove on one side of the st...

Page 63: ...the vertical slots in the swivel mount s wall plate Rotate 360 around the longitudinal axis by fixing on the screw on cone Tilt around the depth axis Tip through horizontal slots in the wall fastenin...

Page 64: ...bus cable M12 plug coupling PUR 15 m Order No 2328556 CAN bus cable M12 plug coupling PUR 20 m Order No 2328557 10 CAN bus termination 120 Ohm bushing Order No 2338042 24 VDC and synchronization 4 Y...

Page 65: ...5 5 7 4 P_02462 OPERATING MANUAL VERSION 07 2014 ORDER NUMBER DOC 2335144 TX transmitter TX transmitter RX receiver RX receiver RX receiver TX transmitter TX transmitter RX receiver Code catching bus...

Page 66: ...ORDER NUMBER DOC 2335144 7 13 6 CONNECTION DIAGRAM FOR CML720I LIGHT CURTAINS WITHOUT CODE CATCHING TX transmitter TX transmitter RX receiver RX receiver RX receiver TX transmitter bushing plug The me...

Page 67: ...NG MANUAL VERSION 07 2014 ORDER NUMBER DOC 2335144 7 13 7 CONNECTION DIAGRAM FOR CML720I HEIGHT LIGHT CURTAINS RX receiver TX transmitter bushing plug The meaning of the numbers is explained in Chapte...

Page 68: ...eceiver must be equipped with the grounding sliding block and must be connected to the grounded portal or nearest ground via a grounding cable Note The hex socket head screw on the sliding nut must be...

Page 69: ...ive when the keys do not respond to input The lock can be deactivated as described below Setting on the ProfiTech M panel Switch off the panel and restart the light curtain power off on Unplug CAN bus...

Page 70: ...ctivated value LEDs on receiver LED 1 green LED 2 yellow LED Color State Description in measuring operation 1 green ON lit up permanently Measuring light curtain ready normal operation Flashing Intern...

Page 71: ...eject a selection function You access this symbol from the previous symbol tick by pressing the key This mode allows you to reject the current value or option parameter by pressing the key Return to s...

Page 72: ...described below Procedure This appears on the receiver s display when the light curtain is switched on 1 Press key the menu shown in the left appears 2 Press key the Mode function is displayed with a...

Page 73: ...esired baud rate is displayed with a bright background 8 Press key the Selection confirmation symbol is displayed with a bright background to the left of the baud rate Either the Reject selection func...

Page 74: ...ress key the menu shown in the left appears 2 Press key the Mode function is displayed with a bright background 3 Press key until the CANopen function is displayed with a bright background 4 Press key...

Page 75: ...of numbers 6 Press key the Selection confirmation symbol is displayed with a bright background to the left of the node ID Either the Reject selection function or Return to selection menu function is...

Page 76: ...rtain s local operating display The first and last beams in the light curtain are shown as bars Procedure This appears on the receiver s display when the light curtain is switched on 1 Press key the m...

Page 77: ...set function is adopted by pressing the key 6 Press key two bar graph fields display the alignment status of the first beam FB First Beam and last beam LB Last Beam Both bar graph fields must be compl...

Page 78: ...y groups are provided They can be connected to terminal X30 The load must always be evenly divided between the two groups Group 1 line protection F3 A Group 2 line protection F3 B The CAN signal for t...

Page 79: ...Tech M P_2194 1 2 3 4 5 X30 6 7 8 9 10 2 1 OPERATING MANUAL VERSION 07 2014 ORDER NUMBER DOC 2335144 7 15 1 CONNECTIONS WITH TWO MOTION UNITS SFM2 Optional CPS CAN Power 230 VAC Switch on CAN bus term...

Page 80: ...h M P_02182 1 2 3 4 5 X30 6 7 8 9 10 2 1 4 3 OPERATING MANUAL VERSION 07 2014 ORDER NUMBER DOC 2335144 7 15 2 CONNECTIONS WITH FOUR MOTION UNITS SFM2 Optional CPS CAN Power 230 VAC Switch on CAN bus t...

Page 81: ...rter The setting takes place via the DIP switch 1 64 Setting sliding table 1 Adress 11 DIP switch 1 2 4 ON Setting sliding table 2 Adress 12 DIP switch 3 4 ON Further sliding tables will be consecutiv...

Page 82: ...ter The setting takes place via the DIP switch 1 64 Setting reciprocator 1 Adress 21 DIP switch 1 3 5 ON Setting reciprocator 2 Adress 22 DIP switch 2 3 5 ON Further reciprocators will be consecutivel...

Page 83: ...via the HU1 sliding table It must be connected before the sliding table assumes its final position Fit the sliding table at a distance of 10 cm from the booth wall to provide access to the face end fo...

Page 84: ...work piece suspension Grounding of spray booth conveyor system and suspension on the building side in accordance with the operating manuals or the manufacturer s information Grounding of all conducti...

Page 85: ...e measured insulation resistance must not exceed 100 M megohms Sparks between conveyor conveyor hooks hangers and work piece can occur if electric contact points between conveyor conveyor hooks hanger...

Page 86: ...no persons are working on the device 5 Switch on key switch 6 Log in to the system parameters with authorization 7 Check if the indicator lights on the motion devices and control units for the gun ma...

Page 87: ...operating staff must receive appropriate system training WARNING Incorrect operation Risk of injury and damage to the device If contact with solvent based paints or cleaning agents causes skin irrita...

Page 88: ...DING COATING OPERATION Ensure that the regular safety checks are carried out in accordance with Chapter 9 2 3 commissioning is carried out in accordance with Chapter 7 17 The steps for starting and en...

Page 89: ...high voltage mustbeshutdownandlockedtopreventitfrombeingswitched back on The spray gun must be separated from the high voltage supply before any cleaning work is started Use only electrically conduct...

Page 90: ...4 must be adhered to for all cleaning work 9 1 3 CLEANING PROCEDURES Incorrect maintenance Risk of injury and damage to the device If contact with powder products or cleaning agents causes skin irrit...

Page 91: ...Observe the safety instructions in Chapter 4 and Chapter 9 1 2 Prior to maintenance Clean system Chapter 9 1 3 After maintenance Carry out a safety checks in accordance with Chapter 9 2 3 Turn on the...

Page 92: ...eck grounding Check compressed air quality Check gun voltage Check powder hoses for bends and sintering 9 2 4 MAINTENANCE PROCEDURES Incorrect maintenance Risk of injury and damage to the device If co...

Page 93: ...ORDER NUMBER DOC 2335144 10INSPECTIONS IN ACCORDANCEWITH DIN EN 50177 2010 If the system is used for electrostatic coating with flammable coating powders testing should be undertaken in accordance wit...

Page 94: ...n while the technical ventilation is not working eff ectively CP FI Test whether the system is safely stopped and the product supply supply air and high voltage are switched off when the ventilation i...

Page 95: ...sistors weekly 5 Measures to take if conductive components are insuffi ciently grounded If suffi cient grounding of conductive parts cannot be ensured their discharge energy must not exceed the permis...

Page 96: ...t The discharge equipment must be interlocked with the spray system such that the high voltage is switched off and that coating cannot take place if the discharge equipment malfunctions CP ME FU S Mea...

Page 97: ...cquer residues must be disposed of in line with statutory requirements Before starting disassembly check whether the supply lines have actually been interrupted and have been depressurized and or de e...

Page 98: ...pare parts lists Billing address Delivery address Name of the person to be contacted in the event of any queries Type of delivery normal mail express delivery air freight courier etc Wearing parts Not...

Page 99: ...nts Light curtains or frequency converters are order related Priority 1 Components that must be on the spare parts list Priority 2 Components that are recommended for the spare parts list Priority 3 L...

Page 100: ...eryimportantchapter Maintenanceandcleaning fortherelevantcomponents Thedescriptionoftroubleshootinganderrorcorrectionfortherespectivecomponents and a list of spare parts wearing parts and accessories...

Page 101: ...Spanish PEA T3 tribo automatic spray guns 351873 German 351874 English 351875 French 351876 Italian 351877 Spanish PEA T3 XL tribo automatic spray guns 351700 German 351701 English 351702 French 35170...

Page 102: ...aterial costs will be borne by us except where these costs are increased due to the subsequent shipment of the device to a location other than the address of the purchaser We do not provide warranty f...

Page 103: ...declare that the supplied version of ProfiTech M complies with the following provisions applying to it 94 9 EC ATEX Directive 2004 108 EC EMC Directive Applied standards in particular DIN EN 1127 1 2...

Page 104: ...104 ProfiTech M OPERATING MANUAL VERSION 07 2014 ORDER NUMBER DOC 2335144...

Page 105: ...105 ProfiTech M OPERATING MANUAL VERSION 07 2014 ORDER NUMBER DOC 2335144...

Page 106: ...rance fr Netherlands WAGNER Systemen Nederland Proostwetering 105 C NL 3543 AC Utrecht Phone 31 30 2410 688 Fax 31 30 2410 765 E mail info wagnersystemen nl Italy WAGNER Itep S p A Via Santa Veccia 10...

Page 107: ......

Page 108: ...CERTI F I E D Order No 2335144 Germany Phone Fax E mail Switzerland Phone Fax E mail...

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