WAGNER ProfiTech M Instrucciones de instalación
II 3D Ex tc IIIB T60°C Dc
ProTech M
Hardware + Installation
Version 07 / 2014
Translation of the Original
Operating Manual
3
ProfiTech M
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
Table of Contents
1 GENERAL 6
1.1 Preface 6
1.2 Warnings, Notices, and Symbols in this Operating Manual 6
1.3 Languages 7
1.4 Abbreviations 7
1.5 Terminology for the Purpose of this Manual 8
2 CORRECT USE 9
2.1 Device Type 9
2.2 Type of Use 9
2.3 Use in Potentially Explosive Areas 9
2.4 Safety Parameters 9
2.5 Processible Working Materials 10
2.6 Reasonably Foreseeable Misuse 10
2.7 Residual Risks 10
3 IDENTIFICATION 11
3.1 Explosion Protection Identication 11
3.1.1 MCM Master Control 11
3.1.2 MCM CPS I/O Control 11
3.2 Type Plate 12
4 GENERAL SAFETY INSTRUCTIONS 13
4.1 Safety Instructions for the Operator 13
4.1.1 Electrical Devices and Equipment 13
4.1.2 Sta Qualications 13
4.1.3 Safe Work Environment 13
4.2 Safety Instructions for Sta 14
4.2.1 Safe Handling of WAGNER Powder Spray Devices 14
4.2.2 Grounding the Device 14
4.2.3 Product Hoses 14
4.2.4 Cleaning 15
4.2.5 Handling Powder Lacquers 15
4.3 Protective and Monitoring Equipment 15
4.4 Safety Feature Identication 16
5 DISCLAIMER 17
5.1 Hardware 17
5.2 Software 17
6 COMPONENT DESCRIPTION 18
6.1 Functional Description 18
6.2 Protective and Monitoring Equipment 18
6.3 Scope of Delivery 18
6.4 MCM Controller Components 19
6.5 Control Unit/Spray Gun Components 22
6.6 Pulse Generator Components 25
6.7 Light Grid Set LGS 25 Components 26
6.8 Kontur 2 Light Curtain Components 26
6.9 Light curtain CML720i Components (from 06/2014) 28
6.10 Motion Equipment Components 30
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ProfiTech M
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
Table of Contents
6.11 Miscellaneous 31
6.12 Technical Data 32
6.12.1 MCM Master Control 32
6.12.2 MCM CPS I/O Control 33
6.12.3 Technical Data for Maximum ProTech M Conguration 34
6.12.4 Rack (10 EPG S2) 35
6.12.5 EPG S2 35
6.12.6 EPG-Sprint X 36
6.13 Compressed Air Quality 37
6.14 Operating Elements on the Master Module 38
6.15 Display Elements Front Side of EPG S2 39
7 ASSEMBLY AND COMMISSIONING 40
7.1 Training the Assembly Sta 40
7.2 Storage Conditions 40
7.3 Installation Conditions 40
7.4 Assembly of the ProTech M Components 41
7.5 Setting Up the Rack 42
7.6 System Description 43
7.6.1 CPS Control Cabinet Design 43
7.6.2 Terminal Descriptions 44
7.6.3 CAN Addresses for MCM System 47
7.7 Connecting the MCM Module 48
7.7.1 Connections on the MCM Master Control 49
7.7.2 Connections on the MCM CPS I/O Control 49
7.7.3 Connection Point for CAN Bus, EPG-Sprint X and Encoder 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 Parameter Setting on the EPG-Sprint X 54
7.11 Power Supply of the EPG Control Units 55
7.12 Connecting the Conveyor Encoder 56
7.13 Connecting the Light Curtains 57
7.13.1 Connection Diagram for "Kontur 2" Light Curtains 57
7.13.2 Installation of the "Kontur 2" Light Curtains 59
7.13.3 Connection Diagram for LGS Light Grid 61
7.13.4 Assembly of CML720i Light Curtains 62
7.13.5 Connection Diagram for CML720i Light Curtains with Code Catching 64
7.13.6 Connection Diagram for CML720i Light Curtains without Code Catching 66
7.13.7 Connection Diagram for CML720i Height Light Curtains 67
7.13.8 Grounding of CML720i Light Curtains 68
7.14 Commissioning the CML720i Light Curtains 69
7.14.1 Setting the Baud Rate 72
7.14.2 Setting Node ID 74
7.14.3 Alignment Operation 76
7.15 Connection of the Motion Technique 78
7.15.1 Connections with Two Motion Units 79
7.15.2 Connections with Four Motion Units 80
7.15.3 Setting Node ID's and Baud Rate on Sliding Table 81
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ProfiTech M
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
Table of Contents
7.15.4 Setting Node ID and Baud Rate on Reciprocator 82
7.15.5 Connecting Spray Gun Blow Out Fixture 83
7.16 Grounding 84
7.17 Commissioning 86
8 OPERATION 87
8.1 Training the Operating Sta 87
8.2 Safety Instructions 87
8.3 Work 88
8.3.1 Starting / Ending Coating Operation 88
9 CLEANING AND MAINTENANCE 89
9.1 Cleaning 89
9.1.1 Cleaning Sta 89
9.1.2 Safety Instructions 89
9.1.3 Cleaning Procedures 90
9.2 Maintenance 91
9.2.1 Maintenance Sta 91
9.2.2 Safety Instructions 91
9.2.3 Safety Checks 92
9.2.3.1 Grounding Check 92
9.2.4 Maintenance Procedures 92
10 INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: 2010 93
11 DISASSEMBLY AND DISPOSAL 97
11.1 Disassembly 97
12 SPARE PARTS 98
12.1 How Can Spare Parts Be Ordered? 98
12.2 Spare Parts Recommendation for the Control Cabinet 99
13 EXTENDED OPERATING MANUAL 100
14 WARRANTY AND CONFORMITY DECLARATIONS 102
14.1 Important Notes Regarding Product Liability 102
14.2 Warranty Claim 102
14.3 CE Declaration of Conformity 103
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ProfiTech M
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL
1 GENERAL
1.1 PREFACE
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.
Warning - possible imminent danger.
Non-observance may result in death or serious injury.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
Note - provides information about particular characteristics and how to proceed.
Notice - a possibly hazardous situation.
Non-observance may result in damage to property.
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 danger 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 the danger and its
consequences.
WARNING
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 danger and its
consequences.
CAUTION
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 danger and its consequences.
HINT
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 operating and service
sta.
The device may only be operated by trained sta and in compliance with this operating
manual.
Operating and service sta should be instructed according to the safety instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
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ProfiTech M
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
This operating manual describes the components and installation of a ProTech M system
(control cabinet, electrical connections and preparation for rst commissioning).
This operating manual is to be used alongside the ProTech M "System Operation"
operating manual , which describes the operation of the entire ProTech 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
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Spare part
W Width
H Height
D Depth
RP Reversal point
LC Light curtain
I/O Input/Output
OK all right
Trigger point
ASR Automatic sine regulation
MP Machine parameters
REZ Recipe parameter
FC Frequency converter, e.g. for motion equipment
Master Control Module = abbreviation for ProTech M
SR Shift register
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ProfiTech M
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning Manual cleaning of devices and device parts with cleaning
agent
Flush Internal ushing with compressed air of parts carrying paint
Sta qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
associated with improper behavior as well as the necessary
protective devices and measures.
Electrically trained
person
Is instructed by an electrician about the tasks assigned to him/
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 based on his/her technical training, knowledge and
experience in relevant provisions.
Skilled person A person, who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge in the areas of explosion protection, protection
from pressure hazards and electric hazards (if applicable) and
is familiar with the relevant and generally accepted rules of
technology so that he/she can inspect and assess the status of
devices and coating systems based on workplace safety.
In accordance with
TRBS 1203 (2010)
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ProfiTech M
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
2 CORRECT USE
2.1 DEVICE TYPE
2.2 TYPE OF USE
The ProTech M controller serves to control the powder coating system's spray guns,
powder conveying device, reciprocators, and sliding table.
2.4 SAFETY PARAMETERS
2.3 USE IN POTENTIALLY EXPLOSIVE AREAS
Controller for automatic powder coating systems
The ProTech M controller may be used in the dust explosion zone (Zone 22) under the
following conditions (see explosion protection identication in Chapter 3.1).
All connections and cable entries not needed (mains output, remote control) are
sealed with dust 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 deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The device may only be operated under the following conditions:
The operating sta must be trained based on this operating manual.
The safety regulations listed in this operating manual must be observed.
The operating, maintenance and repair information in this operating manual must be
observed.
The statutory requirements and accident prevention regulations standards in the
country of use must be observed.
The automatic coating system may only be used if all parameters are set and all
measurements/safety checks are carried out correctly.
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ProfiTech M
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
2.6 REASONABLY FORESEEABLE MISUSE
2.5 PROCESSIBLE WORKING MATERIALS
Types of powder which can be charged electrostatically
Metallic powder
2.7 RESIDUAL 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 Specic measures Lifecycle
phase
Skin contact with
powder lacquers
and cleaning
agents
Handling powder
lacquers and
cleaning agents
Skin irritations, Wear protective
clothing,
Operation,
allergies observe safety data
sheets
maintenance,
disassembly
Powder lacquer
in air outside the
dened working
area
Lacquering
outside the
dened working
area
Inhalation of substances
which are hazardous to
health
Observe work and
operation instructions
Operation,
maintenance
The forms of misuse listed below may result in physical injury or property damage:
Coating work pieces which are not grounded;
Unauthorized conversions or modications to the system;
Working with liquid coating products or moist powder lacquer;
Using defective components, spare parts or accessories other than those described in
the "Accessories" chapter of this operating manual;
Continuing work with a defective or kinked product hose;
Working with incorrectly set values;
Processing food.
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