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ProfiTech M

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC 2335144

4.4

SAFETY FEATURE IDENTIFICATION

Plates bearing information for the user have been attached to the work openings of the
powder coating booth.
The plate size corresponds to the standard category Ø 100 mm; 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 atmosphere!

Forbidden for persons
with a cardiac pacemaker!

Follow the instructions in
the operating manual!

Smoking, fi re, and open
fl ames are prohibited!

Wear electrostatically
conductive footwear!

Danger of crushing!

Risk of tripping!

Do not jump on the

booth fl oor!

Danger of slipping!

Содержание ProfiTech M

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

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 107: ......

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

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