Translation of the Original Operating Manual FM Universal Control Unit for Powder Coating Guns Version 09/2017 EPG S2 P_01486 0102 II 3(2)D IP64 80 C P_00309
Table of Contents 1 GENERL 5 1.1 Preface 5 1.2 Warnings, Notices and Symbols in these Instructions 5 1.3 Languages 6 1.4 bbreviations 6 2 CORRECT USE 7 2.1 Device Type 7 2.2 Type of Use 7 2.3 Use in an Explosion Hazard rea 7 2.4 Safety Parameters 8 2.5 Reasonably Foreseeable Misuse 8 2.6 Residual Risks 8 3 IDENTIFICTION 9 3.1 Explosion Protection Identification 9 3.2 Permissible Device Combinations 9 4 GENERL SFETY INSTRUCTIONS 10 4.1 Safety Instructions for the Operator 10 4.1.1 Electrical Devices and Equipment 10 4.1.2 Personnel Qualifications 10 4.1.3 Safe Work Environment 10 4.2 Safety Instructions for Staff 11 4.2.1 Safe Handling of WGNER Powder Spray Devices 11 4.2.2 Grounding the Device 11 4.2.3 Product Hoses 11 4.2.4 Cleaning 12 4.2.5 Handling Powder Lacquers 12 4.3 Protective and Monitoring Equipment 13 4.4 Safety Feature Identification 14 5 DESCRIPTION 15 5.1 Fields of pplication, Correct Use 15 5.2 Technical Data 16 5.3 Permitted ccessories 18 5.4 Scope of Delivery 18 5.5 Display and Operating Elements 19 5.5.1 Display Elements, Front Side 19 5.5.2 Connections on the Rear Side of the 20 5.5.3 Connections on the Rear Side of the FM 22 5.5.4 CN us Connection on the Rear Side 23 6 SSEMLY ND COMMISSIONING 24 6.1 Training ssembly/commissioning Staff 24 6.2 Storage Conditions 24 6.3 Installation Conditions 24 6.4 Connecting the utomatic Spray Guns 25 6.5 Connecting the Manual Guns 26 6.6 Connection Diagram in the Rack 27 3
6.7 Grounding 28 6.7.1 Grounding the Powder Coating System 30 6.8 Device Settings 31 6.8.1 CN us aud Rate Setting 31 6.8.2 CN us Node ID Setting 32 7 OPERTION 33 7.1 Training the Operating Staff 33 7.2 Safety Instructions 33 7.3 Controllable Spray Guns 34 7.4 Gun Cable Lengths 34 7.5 Control Functions on Control Unit 35 7.5.1 Setting the High Voltage 35 7.5.2 Setting of Current Limiting 36 7.5.3 Settings of High-voltage Characteristic 37 7.5.4 Setting the ir Volume 38 7.5.5 ir Supply Pressure 38 7.6 Diagnosis and Monitoring 39 7.6.1 LED Displays 39 7.7 Emergency Operation 40 7.7.1 ctivation of Emergency Mode 40 7.7.2 Functioning of the Emergency Mode 40 8 CLENING ND MINTENNCE 41 8.1 Cleaning 41 8.1.1 Cleaning Staff 41 8.1.2 Safety Instructions 41 8.1.3 Cleaning Procedures 42 8.2 Maintenance 43 8.2.1 Maintenance Staff 43 8.2.2 Safety Instructions 43 8.2.3 Maintenance Procedures 44 9 INSPECTIONS CCORDING TO DIN EN 50177: 2010 45 10 DISSSEMLY ND DISPOSL 49 10.1 Disassembly 49 10.2 Disposal 49 11 TROULE SHOOTING ND RECTIFICTION 50 11.1 Faults 51 12 CCESSORIES 52 13 SPRE PRTS 53 13.1 How Can Spare Parts e Ordered? 53 13.2 Control Unit 54 14 WRRNTY ND CONFORMITY DECLRTIONS 55 14.1 Important Notes Regarding Product Liability 55 14.2 Warranty Claim 55 14.3 CE Declaration of Conformity 56 14.4 EC Type Examination Certificate 57 14.5 FM Identification FM 58 4
1 GENERL 1.1 PREFCE The operating manual contains information about safely operating, maintaining, cleaning and repairing the device. The operating manual is part of the device and must be available to the operating and service personnel. Operating and service personnel should be instructed according to the safety instructions. The device may only be operated in compliance with this operating manual. This equipment can be dangerous if it is not operated according to the instructions in this operating manual. 1.2 WRNINGS, NOTICES ND SYMOLS IN THESE INSTRUCTIONS Warning instructions in this operating manual highlight particular dangers to users and to the device and state measures for avoiding the hazard. These warning instructions fall into the following categories: Danger - immediate risk of danger. Non-observance will result in death or serious injury. DNGER 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 the hazard and its consequences. Warning - possible imminent danger. Non-observance may result in death or serious injury. WRNING 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 the hazard and its consequences. Caution - a possibly hazardous situation. Non-observance may result in minor injury. CUTION 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 the hazard and its consequences. Notice - a possibly hazardous situation. Non-observance may result in damage to property. NOTICE 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 the hazard and its consequences. Note - provides information about particular characteristics and how to proceed. 5
1.3 LNGUGES The operating manual is available in the following languages: German 2317573 English 2317574 French 2317575 Italian 2317576 Russian 2334207 Chinese 2335799 Hungarian 2338270 Czech 2348860 Spanish 2355652 Danish 2371619 Swedish 2371624 Portuguese 2392066 1.4 REVITIONS Order No. No. Number of pieces Position Marking in the spare parts lists Order number Number Spare part 6
2 CORRECT USE 2.1 DEVICE TYPE Universal control unit for controlling two electrostatic manual or automatic powder spray guns. 2.2 TYPE OF USE The control unit is intended for controlling electrostatic manual and automatic powder spray guns of type -P (2 mj) according to DIN EN 50177. WRNING Incorrect use! Risk of injury and damage to the device. Only connect original WGNER spray guns to the control unit. 2.3 USE IN N EXPLOSION HZRD RE The control unit are intended for use with powder spray guns of types -P up to 2 mj in accordance with the prototype test PT 12 TEX 5001. The control unit may be used in the dust explosion zone (zone 22) under the following conditions: Control unit correctly fitted and connections on rear correctly and securely sealed with associated cover. Not used electrical connections are sealed with protective caps. 7
2.4 SFETY PRMETERS The control unit is only suited for controlling powder spray guns. Wagner International G prohibits any other use! The use of the control unit is only permissible under the following conditions: the operating staff have previously been trained on the basis of this operating manual, the safety regulations listed in this operating manual are observed, the operating, maintenance and repair information in this operating manual is observed, and the statutory requirements and accident prevention regulations standards in the country of use are observed. The control unit may only be used if all parameters are set and all measurements/safety checks are carried out correctly. 2.5 RESONLY FORESEELE MISUSE Coating work pieces which are not grounded Use of defective components and accessories Use with non-authorized power spray guns 2.6 RESIDUL RISKS Residual risks are risks which cannot be ruled out even in the event of correct use. If necessary, warning and prohibition signs at the relevant points of risk indicate residual risks. Residual risk Source Consequences Specific measures Lifecycle phase Skin contact with powder lacquers Handling powder lacquers and Skin irritation, allergies Wear protective clothing Operation, and cleaning cleaning agents observe safety data maintenance, agents sheets disassembly Powder lacquer in air outside the defined working area Lacquering outside the defined working area Inhalation of substances which are hazardous to health Observe work and operation instructions Operation, maintenance 8
3 IDENTIFICTION 3.1 EXPLOSION PROTECTION IDENTIFICTION The device is suited for use in potentially explosive areas, in accordance with Test Certificate PT 12 TEX 5001. 0102 II 3(2)D IP 64 80 C CE: European Communities 0102: Notified body Ex: Symbol for explosion protection II: Device class II 3: Category 3 (Zone 22) (2): Impact on equipment of category 2 D: Ex-atmosphere dust IP64: Protection class 64 80 C: Temperature class: maximum surface temperature < 80 C; 176 F 3.2 PERMISSILE DEVICE COMINTIONS The following powder spray guns may be connected to the : utomatic spray guns Corona spray gun PE-C3, PE-C4 Corona spray gun PE-C3XL, PE-C4XL Tribo spray gun PE-T3 Tribo spray gun PE-T3XL Manual spray guns Corona spray gun PEM-C3, PEM-C4 HiCoat, PEM-C4 Ergo, PEM-X1 Older or other gun types may only be connected to the control unit after first checking their suitability with WGNER. 9
4 GENERL SFETY INSTRUCTIONS 4.1 SFETY INSTRUCTIONS FOR THE OPERTOR Keep this operating manual at hand near the device at all times. lways follow local regulations concerning occupational safety and accident prevention. 4.1.1 ELECTRICL DEVICES ND EQUIPMENT To be provided in accordance with the local safety requirements with regard to the operating mode and ambient influences. May only be maintained by skilled electricians. Must be operated in accordance with the safety regulations and electrotechnical regulations. Must be repaired immediately in the event of problems. Must be decommissioned if they pose a hazard. Must be de-energized before work is commenced on active parts. Secure the device against being switched back on without authorization. Inform staff about planned work. Observe electrical safety regulations. 4.1.2 PERSONNEL QULIFICTIONS Ensure that the device is operated, maintained and repaired only by trained persons. 4.1.3 SFE WORK ENVIRONMENT The floor in the working area must be electrostatically conductive (measurements according to EN 1081). Make sure that all persons within the working area are wearing electrostatic-conductive shoes. Ensure that gloves worn are made of conductive material. The powder release must be electrically interlocked with the powder spray system's exhaust air equipment. Excess coating product (overspray) must be collected up safely. Ensure that there are no ignition sources such as naked flames, sparks, glowing wires, or hot surfaces in the vicinity. No smoking. Maintain sufficient quantities of suitable fire extinguishers and ensure that they are serviceable. The operating company must ensure that an average concentration of powder lacquer in the air does not exceed 50% of the lower explosion limit (LEL = max. permitted concentration of powder to air). If no reliable LEL value is available, the average concentration must not exceed 10 g/m³. 10
4.2 SFETY INSTRUCTIONS FOR STFF lways follow the information in this manual, particularly the general safety instructions and the warning instructions. lways follow local regulations concerning occupational safety and accident prevention. Under no circumstances may anyone fitted with active implants (e.g., a pacemaker) enter the area where the high-voltage field between the spray gun and the work piece to be coated builds up! 4.2.1 SFE HNDLING OF WGNER POWDER SPRY DEVICES Do not point spray guns at people. efore all work on the device, in the event of work interruptions and functional faults: Switch off the energy/compressed air supply. Secure the spray gun against actuation. Relieve pressure on spray gun and device. In case of functional faults: Identify and correct the problem, proceed as described in the "Fault Rectification" chapter. 4.2.2 GROUNDING THE DEVICE The electrostatic charge may, in certain cases, give rise to electrostatic charges on the device. This may result in the formation of sparks or flames when discharging. Ensure that the device is grounded before each coating process. Ground the work pieces to be coated. Ensure that all persons inside the working area are grounded, e.g., by wearing electrostatically conductive shoes. The functionality of grounding cables must be checked regularly (see EN 60204). 4.2.3 PRODUCT HOSES Use only an original WGNER powder hose. 11
4.2.4 CLENING efore starting cleaning or any other manual work, the high voltage in the spray area must be shut down 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 electrically conducting and grounded tanks for cleaning fluids. Preference should be given to non-flammable cleaning fluids. Flammable cleaning liquids may only be used if, after switching off the high voltage, all high-voltage conducting parts are discharged to a discharge energy of less than 0.24 mj before they can be accessed. Most flammable solvents have an ignition energy of around 0.24 mj or 60 nc. The cleaning agent's flash point must be at least 15 K above the ambient temperature. Only mobile industrial vacuum cleaners of design 1 (see EN 60335-2) may be used to remove dust deposits. 4.2.5 HNDLING POWDER LCQUERS When preparing or processing the powder and cleaning the device, take note of the processing regulations laid down by the manufacturer of the powder lacquers being used. Take note of the manufacturer s instructions and the relevant environmental protection regulations when disposing of powder lacquers. Implement the prescribed safety measures, in particular the wearing of safety glasses and safety clothing as well as the use of protective hand cream. Use a mask or breathing apparatus if necessary. To ensure sufficient protection of health and the environment, only operate the device in a powder booth or on a spray wall with activated ventilation (exhaust air). 12
4.3 PROTECTIVE ND MONITORING EQUIPMENT WRNING Protective and monitoring equipment! Risk of injury and damage to the device. Protective and monitoring equipment must not be removed, modified or rendered unusable. Regularly check for perfect functioning. If defects are detected on protective and monitoring equipment, the system must not be operated until these defects are remedied. 13
4.4 SFETY FETURE IDENTIFICTION 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 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 inches) Voltage before main switch Danger of crushing! Explosive atmosphere! Risk of tripping! Forbidden for anyone fitted with active implants (e.g., a pacemaker) must! Do not jump on the booth floor! Danger of slipping! Smoking, fire, and open flames are prohibited! Forbidden for unauthorized persons! Wear electrostatically conductive footwear! Follow the instructions in the operating manual! 14
5 DESCRIPTION 5.1 FIELDS OF PPLICTION, CORRECT USE WRNING Incorrect use! Risk of injury and damage to the device. Only connect original WGNER spray guns to the control unit. The control unit is used to supply air and voltage to two WGNER automatic or manual powder spray guns, in Corona or Tribo versions. The control unit has no controls; various operating statuses are simply displayed. The module is operated with a superordinate controller (e.g. PLC) from which it receives the necessary information. The interface between the and master controller takes place by means of the CNopen. 15
5.2 TECHNICL DT Dimensions: Height Width Depth (without operating elements) Weight 136 mm; 5.35 inches 270 mm; 10.63 inches 300 mm; 11.81 inches 5.5 kg; 12.13 lb Electrical: Mains (C) Frequency C input power Output voltage to guns Output current High voltage Corona current limitation Tribo current measurement Minimum Tribo current limit Maximum Tribo current cut off CN bus IN/OUT 90 VC 250 VC 47 Hz 63 Hz maximum 60 W 2x maximum 22 Vpp 2x maximum 0.9 2x 10-100 kv (adjustable in 1 kv steps) 5 μ - 120 μ (adjustable in 1 μ steps) 0 μ - 20 μ (resolution 0.1 μ) 0 μ - 5 μ (adjustable in 0.1 μ steps) greater than 12 μ (TEX: switching off of the unit) Signal optically separated Protocol: CNopen Release 24 V DC Protection class IP 64 Ex zone II 3(2)D 80 C; 176 F Pneumatic: Input air pressure ir flow 6 x air quantity regulator with CTUL value measurement Required compressed air quality as per ISO 8573.1 Connection hose diameter 0.6 0.8 MPa; 6 8 bar; 87 116 psi maximum 30 m³/h 0.00-6.00 m³/h (adjustable in 0.025 m³/h steps) 6.5.2 (5 μm/+7 C; +44.6 F/0.1 mg/m³) 8 mm; 0.315 inches mbient conditions: Operating temperature range +5 C up to +45 C; +41 F up to +113 F 16
WRNING Exhaust air containing oil! Risk of poisoning if inhaled. Provide compressed air free from oil and water (Quality Standard 3.5.2 according to ISO 8573.1) 3.5.2 = 5 μm / +7 C; +44.6 F / 0.1 mg/m³. Compressed air quality, accessories Danger of damage to the device. NOTICE Operate the control unit only with the prescribed compressed air quality. Only use the control unit with original WGNER accessories. Non-observance of these conditions results in the warranty expiring! mbient conditions: If low-melting powders are used, the ambient temperature may have to be lower than +30 C; +86 F. Volume measures: for volumes specified in Nm³ (standard cubic meters). One cubic meter of a gas at 0 C and 1.013 bar is called norm cubic meter. 17
5.3 PERMITTED CCESSORIES Only the accessories listed in the "ccessories" chapter of this operating manual may be connected to the control unit. The accessories listed in the chapter "ccessories" were included in the EC type examination and are approved for use with the control unit. 5.4 SCOPE OF DELIVERY Stk Order No. Designation 1 2316991 1 2343176 FM (US edition) The standard equipment includes: 1 2322580 Declaration of Conformity 1 2317573 Operating manual, German 1 see Chapter 1.3 Operating manual in local language 18
5.5 DISPLY ND OPERTING ELEMENTS 5.5.1 DISPLY ELEMENTS, FRONT SIDE EPG S2 P_01487 6 5 4 2 1 3 4 5 6 1 LED display: "Operating voltage" The LED lights up green when the operating voltage is activated 2 LED display: "CN Data Communication" The LED lights up green during data communication with the master 3 LED display: "Release" The LED lights up green when enabling has taken place 4 LED display: "ir" The LED lights up green when the air module is activated 5 LED display: "High voltage" The LED lights up green when the high voltage is activated 6 LED display: "Warning/Malfunction" The LED flashes in the event of a warning and lights up red in the event of a malfunction Displays 4-6 exist for both gun and gun. 19
5.5.2 CONNECTIONS ON THE RER SIDE OF THE 1 2 3 4 5 6 7 ir input Lufteingang Made in Switzerland Wagner International G CH 9450 ltstätten Do NOT disconnect under voltage! NICHT unter Spannung trennen! Mains power IN / OUT Netz EIn / usgang Prim. Fuse Sicherung 1.0 T (slow blow) 6...8 bar 87..116 psi Clean and dry air Saubere und trockene Luft 3.5.2 (ISO 8573.1) 0102 II 3(2)D IP64 80ºC PT 12 TEX 5001 Tested / Geprüft EN50050, EN50177 Type / Typ: Serial No.: Serie Nr.: Voltage: Spannung: 90-250 VC 47-63 Hz Line Power: Eingangsleistung: max. 60 W Prot. Class: Schutzklasse: IP 64 For operation all ports must be fitted with a plug or the protection cap. Für den etrieb in der Zone 22 müssen alle nschlüsse mit Stecker oder Schutzkappe versehen sein. Year of build: aujahr: Spraygun Sprühpistole IN CN us OUT Data and Interlock Daten und Verriegelung Output to gun usgang zur Pistole U max. 22 Vpp I max. 0,9 Feeding air Förderluft Dosage air Dosierluft tomizing air Zerstäuberluft Feeding air Förderluft Dosage air Dosierluft tomizing air Zerstäuberluft P_01488 8 17 16 15 14 13 12 11 10 9 8 1 Primary fuse 1 ampere, slow-acting 2 Grounding connection To connect the signal ground 3 Compressed air Inlet The LED lights up green when enabling has taken place Pressure range: 0.6-0.8 MPa; 6-8 bar; 87-116 psi ir volume: 2x maximum 15 m³/h Connection hose diameter 8 mm; 0.315 inches 4 Input: CN bus connector plug CNopen communication signal Release signal 5 Output: CN bus bushing CNopen communication signal Release signal 20
6 Gun connection To connect a Corona or Tribo gun 7 Gun connection To connect a Corona or Tribo gun 8 Fixations For screwing to the rack 9 Cover of the service connection Once the cover has been removed, the DIP switches and rotary switches for the CN bus address, CN bus baud rate and the switch for emergency mode can be set. 10 ir outlet for atomizing air gun 11 ir outlet for dosing air gun 12 ir outlet for feed air gun 13 ir outlet for atomizing air gun 14 ir outlet for dosing air gun 15 ir outlet for feed air gun 16 Mains input terminal Universal input 90-250 VC 17 Mains output terminal To loop the mains through the system 21
5.5.3 CONNECTIONS ON THE RER SIDE OF THE FM 1 2 3 4 5 6 7 ir input Lufteingang Made in Switzerland Wagner International G CH 9450 ltstätten Type 0102 / Typ: FM Do NOT connect or disconnect when ENERGIZED! Controller is suitable for Class II, Division 2, Hazardous (Classified) locations. Prim. Fuse Sicherung 1.0 T (slow blow) Voltage: Spannung: 90-250 VC 47-63 Hz Line Power: Eingangsleistung: max. 65 W FM approved for CL II, Div 2 Grps E, F, & G mbient temp range 5C to 45C T5 For operation all ports must be fitted with a plug or the protection cap. Spraygun Sprühpistole Output to gun usgang zur Pistole U max. 22 Vpp I max. 0,9 Mains power IN / OUT Netz EIn / usgang Use in accordance with control document: 2309729 Serial No. / Year of build: Serie Nr. / aujahr: Overvoltage Category II and pollution Degree 2 IN CN us OUT Data and Interlock Daten und Verriegelung Feeding air Förderluft Dosage air Dosierluft tomizing air Zerstäuberluft Feeding air Förderluft Dosage air Dosierluft tomizing air Zerstäuberluft P_02472 8 17 16 15 14 13 12 11 10 9 8 The model differs only in the version of the rear label from the variant described in Chapter 5.5.2. From a technical standpoint, the FM version is identical to the one described in Chapter 5.5.2. 22
5.5.4 CN US CONNECTION ON THE RER SIDE Connector plug Equipment socket 4 3 3 4 5 P_01508 5 1 2 2 1 IN CN bus OUT Data and interlock 5-pin plug M12, coded No. Signal 1 Shield/housing 2 +24 VDC release 3 GND 4 CN_H 5 CN_L 23
6 SSEMLY ND COMMISSIONING 6.1 TRINING SSEMLY/COMMISSIONING STFF WRNING Incorrect installation/operation! Risk of injury and damage to the device. The commissioning staff must have the technical skills to safely undertake commissioning. The commissioning staff must be familiar with the provisions of the European standards DIN EN 50050-2 and DIN EN 50177. When commissioning and for all work, read and follow the operating manual and safety regulations for the additionally required system components. 6.2 STORGE CONDITIONS Until the point of assembly, the control unit must be stored in a dry location, free from vibrations and with a minimum of dust. The control unit must be stored in closed rooms. The air temperature at the storage location must be between +5 C and +45 C; +41 and +113 F. The relative air humidity at the storage location must not exceed 75%. 6.3 INSTLLTION CONDITIONS The air temperature at the installation site must lie between +5 C and +45 C; +41 F and +113 F. Depending on the powder lacquer used, the maximum permissible ambient temperature for reliable operation can be significantly below +40 C; +104 F. The relative air humidity at the assembly location must not exceed 75%. 24
6.4 CONNECTING THE UTOMTIC SPRY GUNS Tribo spray gun* Corona spray gun tomizing air CN bus output CN bus input Compressed air Inlet Signal ground Mains input terminal Mains output to next control unit P_01490 Powder injector Powder injector e.g., from the powder tank e.g., from the powder tank * Y distributor is needed to divide the different types of air (order No.: 9990149) 25
6.5 CONNECTING THE MNUL GUNS CN bus output CN bus input Compressed air Inlet Signal ground Mains input terminal Mains output to next control unit P_01489 Powder injector Powder injector e.g., from the powder tank e.g., from the powder tank 26
6.6 CONNECTION DIGRM IN THE RCK The CN bus must be closed at the start and end. Master controller CN bus Terminate US end on master controller Mains input terminal Compressed-air connection, min. 1" ir diffuser P_01512 Close on last device with terminating plug (order No. 2321402) 27
6.7 GROUNDING DNGER No Grounding! Risk of explosion and risk of electric shock. Electrostatic control units and the associated spray equipment may only be connected to mains supplies with a protective conductor connection (PE conductor)! WRNING Heavy paint mist if grounding is insufficient! Danger of poisoning. Insufficient paint application quality: Ground all device components. Ground the work pieces to be coated. For safety reasons, the control unit must be properly grounded. The grounding connection to the energy supply (socket) takes the form of the mains connection cable's protective conductor, while that to the work piece/system is via the knurled screw on the rear of the control unit. oth connections are absolutely essential. If installed correctly as described above, the spray gun is grounded via the gun cable between the control unit and spray gun. Good grounding of the work piece is also necessary for optimum powder coating. poorly grounded work piece causes: dangerous electric charging of the work piece, very poor wrap-around, uneven coating, back spraying to the spray gun, i.e., contamination. Prerequisites for perfect grounding and coating are: clean suspension of the work piece to be coated, grounding of spraying booth, conveyor system and suspension on the part of the building site in accordance with the operating manual or the manufacturer's information, grounding of all conductive parts within the working area. The grounding resistance of the work piece must not exceed 1 MΩ (megohm). (Resistance to ground measured at 500 V or 1000 V). The footwear worn by the operators must comply with the requirements of EN ISO 20344. The measured insulation resistance must not exceed 100 MΩ (megohms). 28
The protective clothing, including gloves, must comply with the requirements of EN ISO 1149-5. The measured insulation resistance must not exceed 100 MΩ (megohms). Sparks between conveyor, conveyor hooks (hangers) and work piece can occur if electric contact points between conveyor, conveyor hooks (hangers) and work piece are not sufficiently cleaned and therefore the work pieces are not sufficiently grounded! These sparks can cause heavy radio frequency interference (EMC). 29
6.7.1 GROUNDING THE POWDER COTING SYSTEM P_01506 The control unit is grounded with the grounding cable supplied. The grounding cable is secured to the control unit's grounding connection and the rack with the screws provided. 1 Only use mains cables with grounding strand! 2 Connect grounding cable with booth and signal ground! 3 Connect grounding cable to an uncoated metal part of the booth! 4 Remove all paint from hooks and other hanger parts! 5 Do not wear non-conducting gloves! 6 Wear electrostatically conductive footwear! 7 The floor must be electrostatically conductive! 8 Connect floor and booth with system ground! 30
6.8 DEVICE SETTINGS The settings described below must be made and/or checked on the control unit before commissioning. The baud rate and node number setting for the CN bus are set mechanically using the switches under the service cover. CN bus node ID setting CN bus baud rate setting/emergency operation mode P_01510 6.8.1 CN US UD RTE SETTING The bit rate is set on the 4-way DIP switch using switches 1, 2 and 3. The switch statuses are only read in when the control unit is switched on (powered up). In order for a change in baud rate to take effect, the device must be switched off and on again. The possible settings are described in the following table: Switch CN baud rate Maximum cable length 1 2 3 4 0 0 0 X 1000 kit/s 25 m aud rate 1 2 3 4 0 P_01509 1 ON 0 0 1 X 800 kit/s 50 m 0 1 0 X 500 kit/s 100 m 0 1 1 X 250 kit/s 250 m 1 0 0 X 125 kit/s 500 m 1 0 1 X 100 kit/s 1000 m 1 1 0 X 50 kit/s 1000 m 1 1 1 X 20 kit/s 1000 m Shown example: Factory setting 250 kit/s 31
0123456789 0123456789 0123456789 0123456789 0123456789 VERSION 09/2017 6.8.2 CN US NODE ID SETTING The node IDs for the CN bus are set using two rotary buttons under the service cover. The node IDs can be set between 1 and 100 as follows: Node ID = 10 x value of rotary button on left + value of rotary button on right Examples: Node ID 01 (0/1) Node ID 23 (2/3) 0123456789 Exception: Node ID 100 (0/0) P_01511 The node ID is only read in and calculated when the control unit is switched on (powered up). For a change to the node ID to take effect, the control unit must be switched off and on again. 32
7 OPERTION 7.1 TRINING THE OPERTING STFF WRNING Incorrect operation! Risk of injury and damage to the device. The operating staff must be qualified to operate the entire system. efore work commences, the operating staff must receive appropriate system training. The operating staff must be familiar with the provisions of European standards DIN EN 50050-2 and DIN EN 50177. 7.2 SFETY INSTRUCTIONS WRNING Incorrect operation! Risk of injury and damage to the device. If contact with powder products or cleaning agents causes skin irritation, appropriate precautionary measures must be taken, e.g., wearing protective clothing. The footwear worn by operating staff must comply with EN ISO 20344. The measured insulation resistance must not exceed 100 megohms. The protective clothing, including gloves, must comply with EN ISO 1149-5. The measured insulation resistance must not exceed 100 megohms. 33
WRNING Incorrect installation/operation! Risk of injury and damage to the device. When commissioning and for all work, read and follow the operating manual and safety regulations for the additionally required system components. 7.3 CONTROLLLE SPRY GUNS Two powder spray guns can be connected to the control unit. These two guns are controlled totally independently of one another. The automatic guns are activated and deactivated via the superordinate controller. The gun types which can be controlled are listed in Chapter 3.2. 7.4 GUN CLE LENGTHS Gun cables are available in the following standard lengths: 5 m; 16.40 ft, 10 m; 32.81 ft and 20 m; 65.62 ft. Note: Maximum permitted gun cable length 35 m; 114.83 ft. Keep the cable length as short as possible as the performance of the gun is reduced with each additional meter of cable. 34
7.5 CONTROL FUNCTIONS ON CONTROL UNIT The control unit does not have its own operating or display elements. ll specifications (set points) and displays (actual values) are transferred by electric signals from a master controller via the CN bus. The software in the master controller determines the input options for set points and displays of the current actual values. 7.5.1 SETTING THE HIGH VOLTGE The set point high voltage of both channels on the control unit can be set independently of each other and the actual calculated high voltage value can be shown on the central controller. Note: The specified high voltage value is only reached when idling and is reduced as soon as current flows. Voltage [kv] Current [μ] The high voltage can be predefined in 1 kv steps between 10 and 100 kv. The graphic shows the characteristic curves for three different high-voltage settings. You can see from the blue curve that a setting of 60 kv allows a maximum current of 110 μ. 35
7.5.2 SETTING OF CURRENT LIMITING The spray current limitation can be set and measured independently in both of the control unit's channels. If the measured spray current reaches or exceeds the set value, the high voltage is adjusted downwards until the set spray current is reduced to maximum. Current [μ] Voltage [kv] The current limitation can be predefined in 1 μ steps between 5 and 120 μ. The graphic shows the characteristic curves for three different current restrictions. You can see from the blue curve that the voltage reduces quickly with a low current restriction. 36
7.5.3 SETTINGS OF HIGH-VOLTGE CHRCTERISTIC Regardless of the high voltage and spray current limitation set, the characteristic curve of the voltage/current curve can be set on the control unit. Three levels are possible: 1. Standard level -> maximum performance 2. Medium level ->reduced performance 3. Soft level -> greatly reduced performance Properties of the characteristic curve Field of application/remarks Standard level for poorly rechargeable types of powder Open-circuit voltage 100 kv for high powder application Maximum current 120 μ (Current limiting) This setting corresponds to the usual WGNER high-voltage modules and control units. Medium level for small surfaces Open-circuit voltage 100 kv for types of powder that recharge well Maximum current 120 μ (Current limiting) To reduce the effects of overcoating such as craters and orange peel. Increasing the open-circuit voltage allows for a greater distance between the spray gun and the work piece while maintaining sufficient powder charging. for types of powder that recharge well Soft level Open-circuit voltage 100 kv for small powder application Maximum current 80 μ for post-coatings Current [μ] Voltage [kv] The characteristic slope can be set at three levels. The graphic shows the characteristic curves for the three different slopes. 37
The defined field of application should only be seen as a guideline and must be adjusted to the type of powder, the distance to the work piece and the work piece geometry. The combination of high-voltage setting, current limitation and characteristic slope results in a large number of settings options for each coating situation. 7.5.4 SETTING THE IR VOLUME The set point air volume in all 6 channels on the control unit can be set independently of each other and the actual air volume measured can be shown on the central controller. The air volume can be set in 0.025 Nm³/h steps between 0.00 Nm³/h and 6.00 Nm³/h. Note that depending on the application, cases may arise where the maximum flow rate cannot be reached. In this case, the control unit will issue a warning and the maximum set point must be reduced. These maximum values can be found in the instructions for the various injectors and guns. 7.5.5 IR SUPPLY PRESSURE The control units are calibrated in the factory to a primary pressure of between 0.6-0.8 MPa; 6-8 bar; 87-116 psi. It is important that the atmospheric pressure supply line has a large cross-section and that the air supply pressure does not drop during high demand. 38
7.6 DIGNOSIS ND MONITORING 7.6.1 LED DISPLYS 9 colored LEDs show various states, activities and malfunctions. P_01505 6 5 4 2 1 3 4 5 6 1 LED Power Lights up green as soon as the device is switched on 2 LED CN Lights up green during the data communication with the master controller 3 LED Release Lights up green when the 24 V release is present 4 LED air ON (gun /gun ) Lights up green when the air controller works 5 LED high voltage ON (gun /gun ) Lights up green when high voltage is switched on 6 LED malfunction Lights up red when an error has occurred 39
7.7 EMERGENCY OPERTION The has a simple emergency mode. The aim of the emergency mode is to permit minimal further work should the CN bus or superordinate controller fail. The emergency mode parameters must be set before the CN bus fails, otherwise emergency mode does not function. 7.7.1 CTIVTION OF EMERGENCY MODE In order to activate emergency mode, the DIP switch 4 must be set to "ON" (see figure below). The switch status is only read in when the device is switched on (powered up). So first set the switch and then restart the device. 1 2 3 4 1 2 3 4 Emergency mode deactivated Emergency mode activated P_01507 7.7.2 FUNCTIONING OF THE EMERGENCY MODE The coating system is activated and deactivated using the release hardware line. If the release is present, the coating system is activated. Unless the set points in the emergency mode parameter set are set to "0", both guns are always activated. When emergency mode is activated, the power LED flashes and the CN LED remains dark. In addition to emergency mode activation, an error reset is performed for every positive flank of the release signal. The device's CN transceiver is switched off. This means that the device cannot send or receive messages. 40
8 CLENING ND MINTENNCE 8.1 CLENING 8.1.1 CLENING STFF Cleaning work should be undertaken regularly and carefully by qualified and trained staff. The staff must be familiar with the DIN EN 50050-2 and DIN EN 50177 provisions. They should be informed of specific hazards during their training. The following hazards may arise during cleaning work: Health hazard from inhaling powder lacquer Use of unsuitable cleaning tools and aids 8.1.2 SFETY INSTRUCTIONS DNGER Explosive powder/air mixes! Danger to life and equipment damage. efore starting cleaning or other manual work, the high voltage must be shut down and locked to prevent it from being switched back on! The spray gun must be separated from the high-voltage supply before any cleaning work is started! Use only electrically conductive tanks for cleaning liquids! Ground the tank! Preference should be given to non-flammable cleaning fluids. Flammable cleaning liquids may only be used if, after switching off the high voltage, all high-voltage conducting parts are discharged to a discharge energy of less than 0.24 mj before they can be accessed. Most flammable solvents have an ignition energy of around 0.24 mj or 60 nc. The cleaning agent's flash point must be at least 15 K above the ambient temperature. Only mobile industrial vacuum cleaners of design 1 (see EN 60335-2) may be used to remove dust deposits. 41
WRNING Incorrect maintenance! Risk of injury and damage to the device. If contact with powder products or cleaning agents causes skin irritation, appropriate precautionary measures must be taken, e.g., wearing protective clothing. The footwear worn by operating staff must comply with EN ISO 20344. The measured insulation resistance must not exceed 100 megohms. The protective clothing, including gloves, must comply with EN ISO 1149-5. The measured insulation resistance must not exceed 100 megohms. 8.1.3 CLENING PROCEDURES The cleaning intervals should be adapted by the operator depending on the level of use and if necessary the level of soiling. If in doubt, we recommend contacting WGNER's specialist personnel. The valid health and safety specifications and the safety instructions provided in Chapter 4 must be adhered to for all cleaning work. 42
8.2 MINTENNCE 8.2.1 MINTENNCE STFF Maintenance work should be undertaken regularly and carefully by qualified and trained staff. They should be informed of specific hazards during their training. The following hazards may arise during maintenance work: Health hazard from inhaling powder lacquer Use of unsuitable tools and aids Once the maintenance work is complete, the device must be checked by a qualified person to ensure a reliable condition. 8.2.2 SFETY INSTRUCTIONS DNGER Incorrect maintenance/repair! Danger to life and equipment damage. Repair or replacement of devices or parts of devices are only allowed to be performed outside the hazard area by qualified personnel. DNGER Incorrect maintenance/repair! Risk of injury and damage to the device. Repairs and part replacement may only be carried out by specially trained staff or a WGNER service center. efore all work on the device and in the event of work interruptions: - Switch off the energy/compressed air supply. - Relieve spray gun and device pressure. - Secure the spray gun against actuation. Observe the operating and service manual for all work. 43
WRNING Incorrect maintenance! Risk of injury and damage to the device. If contact with powder products or cleaning agents causes skin irritation, appropriate precautionary measures must be taken, e.g., wearing protective clothing. The footwear worn by operating staff must comply with EN ISO 20344. The measured insulation resistance must not exceed 100 megohms. The protective clothing, including gloves, must comply with EN ISO 1149-5. The measured insulation resistance must not exceed 100 megohms. 8.2.3 MINTENNCE PROCEDURES The maintenance intervals should be adapted by the operator depending on the level of use and if necessary the level of soiling. If in doubt, we recommend contacting WGNER's specialist personnel. The valid health and safety specifications and safety instructions provided in Chapter 4 must be adhered to for all maintenance work. Maintenance work low out gun and check for sintering Check gun settings Check gun discharge pressure low out powder hoses Check grounding Check compressed air quality Check gun voltage Check powder hoses for bends and sintering Time stamp per shift weekly x x x x x x x x 44
9 INSPECTIONS CCORDING TO DIN EN 50177: 2010 If the system is used for electrostatic coating with flammable coating powders, testing should be undertaken in accordance with DIN EN 50177: 2010-04 as per Table 3 and Table 4. 45
Section Type of inspection Requirements Inspection by 1 Checking the effectiveness of technical ventilation 2 Link between technical ventilation equipment and high voltage, compressed air and coating material supply Checking the effectiveness of technical ventilation The technical ventilation should be interlocked such that the powder feed and high voltage cannot be switched on, while the technical ventilation is not working effectively. Type of inspection Inspection interval TP/SP ME Measurements of air flow speed/ air quantities Check the differential pressure indicator SP FI Test whether the system is safely stopped and the product supply, supply air, and high voltage are switched off when the ventilation is shut down. continuously annually 3 Parts carrying high voltage outside the spray area Legend: MF = Manufacturer ER = Employer SP = Skilled person FPO = Fire prevention officer ELT = Electrician TP = Trained person Parts carrying high voltage outside the spray area must be routed such that discharges which put people at risk do not occur. FI = Function inspection ME = Measurement OC = Organization check VI = Visual inspection CM = Constant monitoring TT = Technical testing SP FI Inspect and test (e.g., by measurement) whether all parts carrying high voltage do not result in discharge which puts people at risk. weekly 46
Section Type of inspection Requirements Inspection by 4 Effectiveness of grounding ll the system's conductive elements, such as floors, walls, ceilings, protective grating, transport equipment, work pieces, powder tanks, machines or construction parts etc. in the spray area, with the exception of parts which carry high voltage during operation, must be connected to the grounding system. Parts of the booth must be grounded in accordance with EN 12215. 5 Measures to take if conductive components are insufficiently grounded 6 Ground leaking resistance from the work piece attachment point Legend: MF = Manufacturer ER = Employer SP = Skilled person FPO = Fire prevention officer ELT = Electrician TP = Trained person If sufficient grounding of conductive parts cannot be ensured, their discharge energy must not exceed the permissible value. The resistance to ground of every work piece's locating point must not exceed 1 megohm (measurement voltage must be 1000 V). The form of construction of the work piece mount must guarantee that the work pieces remain grounded during coating. FI = Function inspection ME = Measurement OC = Organization check VI = Visual inspection CM = Constant monitoring TT = Technical testing Type of inspection Inspection interval SP VI/ME/CM Visual check of ground connections, perform function test on grounding switch, measurement of grounding resistors. SP ME/CM Measurement of discharge energy. SP ME/CM Measure resistance to ground (work piece receiver - ground potential) max. 1 megohm @ 1000 V. weekly weekly weekly 47
Section Type of inspection Requirements Inspection by 7 Measures to take if the work pieces are insufficiently grounded 8 Effectiveness of the manually or automatically actuated fire extinguishing systems (room protection system) Legend: MF = Manufacturer ER = Employer SP = Skilled person FPO = Fire prevention officer ELT = Electrician TP = Trained person If sufficient work piece grounding in accordance with section 6 cannot be ensured, appropriate equipment, e.g., ionizers, must be used to discharge electric charges on the work piece. Such equipment must not exceed the permitted discharge energy of the spray systems with which it is used. In terms of permitted discharge energy, this equipment must be put through the same inspections as the powder spray systems used with it. 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. Effectiveness of the manually or automatically actuated fire extinguishing systems (room protection system). FI = Function inspection ME = Measurement OC = Organization check VI = Visual inspection CM = Constant monitoring TT = Technical testing Type of inspection Inspection interval SP ME/FU/SÜ Measurement of discharge energy, check the monitoring equipment's test function by triggering it. HE/S FI Trigger fire extinguishing system, observe manufacturer's requirements. weekly 6 months 48
10 DISSSEMLY ND DISPOSL 10.1 DISSSEMLY WRNING Incorrect disassembly! Risk of injury and damage to the device. efore starting disassembly: - Switch off the energy/compressed air supply. - Ensure that all system components are grounded. - Secure system against being switched back on without authorization. Observe the operating manuals for any work. Procedure: 1. Switch off the system. 2. Lock the compressed air supply and decompress system. 3. Release electrical cable on control unit. 4. Detach hose for compressed air supply on control unit. 5. Disconnect hoses for feed air, dosing air and atomizing air on the control unit. 6. Remove grounding cable on control unit. 7. Loosen retaining nuts and dismount control unit. 10.2 DISPOSL NOTICE Do not dispose of used electrical equipment with household refuse! In accordance with European Directive 2012/19/EU on the disposal of used electrical equipment and its implementation in national law, this product may not be disposed of with the household refuse, but must be recycled in an environmentally correct manner. WGNER or one of our dealers will take back your used WGNER waste electrical or electronic equipment and will dispose of it for you in an environmentally friendly way. Please contact one of our service points, one of our representatives or us directly to arrange this. 49
11 TROULE SHOOTING ND RECTIFICTION DNGER Incorrect maintenance/repair! Risk of injury and damage to the device. Repairs and part replacement may only be carried out by specially trained staff or a WGNER service center. efore all work on the device and in the event of work interruptions: - Switch off the energy/compressed air supply. - Relieve spray gun and device pressure. - Secure the spray gun against actuation. Observe the operating and service manual for all work. DNGER Incorrect maintenance/repair! Danger to life and equipment damage. WGNER devices, protective systems and safety, monitoring and control equipment may only be maintained/repaired as defined in Directive 2014/34/EC (TEX) by trained WGNER service personnel or capable persons in accordance with TRS 1203! Note national regulations! Repair or replacement of devices or parts of devices may only be performed outside the hazard area! 50
11.1 FULTS In the event of malfunctions, the red "Malfunction" LED lights up. The malfunction is described in detail in the superordinate controller. P_01498 51
12 CCESSORIES Pos K Stk Order No. Designation 1 2321402 CN bus termination 1 2320127 CN bus connection cable, 0.6 m; 1.97 ft 1 2320128 CN bus connection cable, 2.0 m; 6.56 ft 1 2320129 CN bus connection cable, 5.0 m; 16.40 ft 1 2320130 CN bus connection cable, 10.0 m; 32.81 ft 1 2321529 Connection set 1 2321744 Set of stickers, gun numbers 1-32 52
13 SPRE PRTS 13.1 HOW CN SPRE PRTS E ORDERED? lways supply the following information to ensure delivery of the right spare part: Order number, designation and quantity The quantity need not be the same as the number given in the quantity column "Stk" on the list. This number merely indicates how many of the respective parts are used in each component. The following information is also required to ensure smooth processing of your order: ddress for the invoice ddress for delivery Name of the person to be contacted in the event of any queries Type of delivery (normal mail, express delivery, air freight, courier, etc.) Identification in spare parts lists Explanation of column "K" (labeling) in the following spare parts lists. = Wearing parts Note: These parts are not covered by warranty terms = Not part of standard equipment, available, however, as additional extra. WRNING Incorrect maintenance/repair! Risk of injury and damage to the device. Repairs and part replacement may only be carried out by specially trained staff or a WGNER service center. efore all work on the device and in the event of work interruptions: - Switch off the energy/compressed air supply. - Ensure that all system components are grounded. - Secure the device against being switched back on without authorization. Observe the operating and service manual for all work. 53
13.2 CONTROL UNIT Pos K Stk Order No. Designation 1 2316991 control unit 1 2343176 FM control unit (US version) 2 9951117 Slow fuses 1.0 (included in ) 54
14 WRRNTY ND CONFORMITY DECLRTIONS 14.1 IMPORTNT NOTES REGRDING PRODUCT LIILITY s a result of an EC regulation effective from January 1, 1990, the manufacturer shall only be liable for his product if all parts originate from him or are approved by him, and if the devices are properly mounted, operated and maintained. The manufacturer will not be held liable or will only be held partially liable if third-party accessories or spare parts have been used. With genuine WGNER accessories and spare parts, you have the guarantee that all safety regulations are complied with. 14.2 WRRNTY CLIM Full warranty is provided for this device: We will at our discretion repair or replace free of charge all parts which within 24 months in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by the purchaser are found to be wholly or substantially unusable due to causes prior to the sale, in particular faulty design, defective materials or poor workmanship. The type of warranty provided is such that the device or individual components of the device are either replaced or repaired as we see fit. The resulting costs, in particular shipping charges, road tolls, labour and material 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 for damage that has been caused or contributed to for the following reasons: Unsuitable or improper use, faulty assembly or commissioning by the purchaser or a third party, normal wear, negligent handling, defective maintenance, unsuitable coating products, substitute products and the influence of chemical, electrochemical or electrical agents, except when the damage is attributable to us. Components that have not been manufactured by WGNER are subject to the original warranty of the manufacturer. Replacement of a component does not extend the period of warranty of the device. The device should be inspected immediately upon receipt. To avoid losing the warranty, we or the supplier company are to be informed in writing about obvious faults within 14 days upon receipt of the device. We reserve the right to have the warranty compliance met by a contracting company. The services provided by this warranty are dependent on evidence being provided in the form of an invoice or delivery note. If the examination discovers that no warranty claim exists, the costs of repairs are charged to the purchaser. It is clearly stipulated that this warranty claim does not represent any constraint on statutory regulations or regulations agreed to contractually in our general terms and conditions. Wagner International G 55
14.3 CE DECLRTION OF CONFORMITY Herewith we declare that the supplied version of, Order No. 2316991 complies with the following provisions applying to it: 2014/34/EC (TEX Directive) 2014/30/EC (EMC Directive) 2011/65/EC (RoHS Directive) 2012/19/EC (WEEE Directive) pplied standards, in particular: EN ISO 12100: 2010 EN 60204-1:2006+1:2009+:2010 EN 60529:1991+1:2000+2:2013 EN 50050-2:2013 EN 50177:2009+1:2012 EN 60079-0:2012+11:2013 EN 60079-31:2014 EN 1127-1:2011 EN 61000-6-2:2005+:2011 EN 61000-6-4:2007+1:2011 EN ISO/IEC 80079-34:2011 pplied national technical standards and specifications: DGUV-I 209-052 Identification: 0102 II 3(2)D IP 64 80 C CE Declaration of Conformity The Declaration of Conformity is enclosed with this product. If needed, further copies can be ordered through your WGNER dealer by specifying the product name and serial number. Order number: 2322580 56
14.4 EC TYPE EXMINTION CERTIFICTE 57
14.5 FM IDENTIFICTION FM The FM control unit is FM approved in the US and Canada using configuration drawing no. 2309729. P_00309 Special conditions of use: The source electrical connection for the Control Units are to be connected in an unclassified (ordinary) location only. 58