WAGNER ProfiTech M Original Operating Manual

II 3D Ex tc IIIB T60°C Dc

Pro Tech M

Hardware + Installation

Version 07 / 2014

Translation of the Original

Operating Manual

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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 Identi cation 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 Quali cations 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 Identi cation 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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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 Pro Tech M Con guration 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 Pro Tech 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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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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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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This operating manual describes the components and installation of a Pro Tech M system

(control cabinet, electrical connections and preparation for  rst commissioning).

This operating manual is to be used alongside the Pro Tech M "System Operation"

operating manual , which describes the operation of the entire Pro Tech 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 Pro Tech M

SR Shift register

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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 quali cations

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 su cient 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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2 CORRECT USE

2.1 DEVICE TYPE

2.2 TYPE OF USE

The Pro Tech 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 Pro Tech M controller may be used in the dust explosion zone (Zone 22) under the

following conditions (see explosion protection identi cation 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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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 Speci c 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

de ned working

area

Lacquering

outside the

de ned 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 modi cations 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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3 IDENTIFICATION

3.1 EXPLOSION PROTECTION IDENTIFICATION

3.1.1 MCM MASTER CONTROL

3.1.2 MCM CPS I/O CONTROL

The device is suitable for use in potentially explosive areas (Zone 22).

All connections and cable entries not needed must therefore be sealed.

System type: Pro Tech M controller

Manufacturer: J. Wagner AG

CH - 9450 Altstätten

II 3D Ex tc IIIB T60° C Dc

CE: European Communities

Ex: 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 temperature

Dc: Device protection level, suitable for use in Zone 22

System type: Pro Tech M controller

Manufacturer: J. Wagner AG

CH - 9450 Altstätten

II 3D Ex tc IIIB T60° C Dc

CE: European Communities

Ex: 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 temperature

Dc: Device protection level, suitable for use in Zone 22

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ProfiTech M

Type / Typ:

Serie Nr.:

Serial No.:

Eingangsspannung:

Input Voltage:

Eingangsleistung:

Input Power:

MCM Master Control

24VDC

max. 17 W

Baujahr:

Year of manufactur:

J. Wagner AG

CH 9450 Altstätten Made in Switzlerland

II 3D Ex tc IIIB T60ºC Dc

Type / Typ:

Serie Nr.:

Serial No.:

Eingangsspannung:

Input Voltage:

Eingangsleistung:

Line Power:

Vorsicherung:

Main fuse:

MCM CPS I/O Control

230/400VAC 50/60Hz

max. 5.1kW

35A

Baujahr:

Year of manufactur:

J. Wagner AG

CH 9450 Altstätten Made in Switzerland

II 3D

Für den Betrieb in Zone 22 müssen

alle Kabeleinführungen durch ein

Kabel oder Stopfen verschlossen sein.

For operation in Zone 22 all cable

grommets must be closed with a

cable or a plug.

Ex tc IIIB T60ºC Dc

P_02465

1

2

1

3

2

3

4

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3.2 TYPE PLATE

1 Serial number

2 Input voltage

3 Input power

4 Back-up fuse

5 Explosion protection information

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4 GENERAL SAFETY INSTRUCTIONS

4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR

4.1.1 ELECTRICAL DEVICES AND EQUIPMENT

4.1.2 STAFF QUALIFICATIONS

4.1.3 SAFE WORK ENVIRONMENT

Keep this operating manual at hand near the device at all times.

Always follow local regulations concerning occupational safety and accident prevention.

To be provided in accordance with the local safety requirements with regard to the

operating mode and ambient in uences.

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 sta

about planned work.

Observe electrical safety regulations.

Ensure that the device is operated, maintained and repaired only by trained persons.

The  oor in the working area must be electrostatically conductive (measurements

according to EN 1081 and EN 61340-4-1).

The footwear worn by the operators must comply with the requirements of

EN ISO 20344. The measured insulation resistance must not exceed 100 megohms.

The protective clothing, including gloves, must comply with the requirements of

EN ISO 1149-5. The measured insulation resistance must not exceed 100 megohms.

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  ames, sparks, glowing wires,

or hot surfaces in the vicinity. Do not smoke.

Maintain su cient quantities of suitable  re 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.

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4.2.1 SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES

4.2.2 GROUNDING THE DEVICE

4.2.3 PRODUCT HOSES

4.2 SAFETY INSTRUCTIONS FOR STAFF

Only use an original Wagner powder hose.

The electrostatic charge may, in certain cases, give rise to electrostatic charges on the

device. This may result in the formation of sparks or  ames 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).

Always follow the information in this manual, particularly the general safety instructions

and the warning instructions.

Always follow local regulations concerning occupational safety and accident

prevention.

Under no circumstances may people with pacemakers enter the area where the high-

voltage  eld between the spray gun and the work piece to be coated builds up!

Do not point spray guns at people.

Before all work on the device, in the event of work interruptions and functional faults:

- Switch o 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 Recti cation" chapter.

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4.2.4 CLEANING

4.2.5 HANDLING POWDER LACQUERS

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.

Take 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 su cient protection of health and the environment, only operate the device

in a powder booth or on a spray wall with activated ventilation (exhaust air).

Before 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  uids.

Preference should be given to non- ammable cleaning  uids.

Flammable cleaning liquids may only be used if, after switching o 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  ammable solvents have an ignition energy of around 0.24 mJ or 60 nC.

The cleaning agent's  ash 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.

4.3 PROTECTIVE AND MONITORING EQUIPMENT

Protective and monitoring equipment must not be removed, modi ed 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.

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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,  re, and open

 ames are prohibited!

Wear electrostatically

conductive footwear!

Danger of crushing!

Risk of tripping!

Do not jump on the

booth  oor!

Danger of slipping!

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Any amendments by the user or any third party to the structure of the control cabinet

delivered by J. WAGNER GmbH, in particular in respect of the electric controller, require the

written permission of J. WAGNER GmbH.

Any amendments, which were not permitted, immediately lead to the exclusion of all

warranty, 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 systems or controllers intended for sale or for internal use requires the written

permission of J. WAGNER GmbH.

Any amendments by the user or third parties of the software delivered by J. WAGNERGmbH,

requires the written permission of J. WAGNER GmbH.

Any amendments, which were not permitted, immediately lead to the exclusion of all

warranty, liability and guarantee claims by the manufacturer.

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6 COMPONENT DESCRIPTION

6.1 FUNCTIONAL DESCRIPTION

The Pro Tech M controller is used in automatic coating systems. The controller controls:

Powder output quantity

Powder atomization

High-voltage

Current limitation

Motion technology

Gap control

Height control

Depth control

Quantity Order No. Designation

1Pro Tech M controller, consisting of:

1 2330000 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 Operating manual in local language

6.3 SCOPE OF DELIVERY

6.2 PROTECTIVE AND MONITORING EQUIPMENT

Protective and monitoring equipment!

Risk of injury and damage to the device.

Protective and monitoring equipment must not be removed,

modi ed 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.

WARNING

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6.4 MCM CONTROLLER COMPONENTS

MCM Master 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/output module

Main switch: Order No. 2331260

Main switch, 3-pin 11.5 kW for AC supply of MCM CPS I/O Control

Module

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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

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WAGNER ProfiTech M Original Operating Manual

WAGNER ProfiTech M Original Operating Manual

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