Magic Flow English - Finishing Brands EUROPE
Contents
1. Einzelaufnehmer Feb 2011 Page 60 of 74 Magic Flow Rev 3 0 Software release 02 2011 Volumensensor Volume sensor Wahlweise Sitz des Einzelaufnehmers Optional seat of single pickup Einlass Inlet Auslass Outlet Ansicht View Anschlussbild Mounting face Befestigungsschraube Fastening screw Spare parts for volumeter 2K 2015 The following spare parts and wear parts are available for the volumeter Pair of gear wheels Shaft gear wheel Disc washer material PTFE 2K 2057 or 2K 2019 2K 2020 Disc washer material Viton FEP sheathed 2K 2058 Other volumeters are available on request higher or lower resolutions various bearings Page 61 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 8 4 4 Airflow control for atomizing air LG 518 GSP part no 2K 2053 DC 24 V PNP Ausgang Analog Ausgang LED Anzeige Lufterfassungsbereich 0 5 15 m s Abmessungen Schaltstrom Betriebsspannung M Umgebungstemperatur C 76 80 EG N gt 76 i 55 yeh Pot Pot Pot LED LED LED LN 520 GSP LN 520 GA LG 518 GSP LG 518 GA LG 522 GSP 24 DC 20 20 70 Bereitschaftszeit s 20 40 Geh usewerkstoff PBT PET PBT Ms Ni PBT Ms Ni PBT Ms Ni Schutzart EN 60529 IP 67 D 20 40 60 80 100 PNP Ausgang PNP output Analog Ausgang Analog output2. We wish to point out here that a thorough knowledge of how the system works along with careful study of this manual and proper operation of the apparatus only by suitably trained personnel from the start will result in more efficient operation longer trouble free service and faster easier troubleshooting For your safety please also refer to the service manuals for peripheral equipment i e pumps guns and electrostatic equipment If you have any questions regarding the equipment please contact our distributors or us We will be pleased to help you 1 2 Identification of the apparatus If you have any questions regarding the product please note the exact type identification of the apparatus with the serial number You will find it on the type plate of the apparatus This will help to identify the apparatus with regard to version and equipment so that we can offer you the appropriate assistance 1 3 Warranty All ITW equipment and spare parts are manufactured from the best materials and using the most modern production processes Should you still have cause for complaint send the defective part or the defective assembly directly to ITW or to our distributor Please understand that we cannot accept any un franked delivery If your warranty claim is legitimate we will refund shipping costs to you We will check replace or repair defective parts that fall within the warranty The repair will be carried out at our company If you wish the
3. 28 4 4 29 FE ge 30 4 G 31 4 7 32 4B Page 13 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 4 8 Fluid connections Depending on the number of components the fluid handling section must be supplied with at least one main colour one hardener and one flushing agent The outlet of the static mixer must be connected to the gun guns by a suitable fluid hose please refer to length and nominal pressure The hoses must be equipped with suitable hose connections according to the apparatus The threads must be in a perfect condition and must seal under pressure Page 14 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 5 Operating the system 5 1 General 5 1 1 Turning on the Apparatus Turn on the apparatus by turning the main switch to the ON position Only turn the apparatus on if the control cabinet is closed high voltage Opening of the control cabinet when the apparatus is ON must only be carried out by qualified personnel and service technicians Generally it is not necessary to turn off the apparatus If the apparatus is in main menu mode and has been cleaned the screen will independently turn off after an adjustable period of time see system settings value Standby Do not turn the apparatus off in the filled state as control of the pot life will then no longer be possible resulting in a risk of material hardening in the apparatus 5 1 2 Numerical input To set the differen
4. LED Anzeige LED display Lufterfassungsbereich 0 5 15 m s Air detection range 0 5 15 m s Ausfiihrung Design Abmessungen Dimensions Erfassungsbereich Detection range Page 62 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 Ausgang Output Best Nr Order no Typ Type Schaltstrom Switching current Last Load Betriebsspannung Operating voltage Stromaufnahme Power consumption Umgebungstemperatur Ambient temperature Temperaturgradient Temperature gradient Bereitschaftszeit Standby time Reaktionszeit typ Typical reaction time Geh usewerkstoff Casing material Anzeige Str mung Flow display Schutzart Protection type Anschluss Connection 2 m PVC Kabel 3x0 5 mm 2 m PVC cable 3x0 5 mm Page 63 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 8 4 5 Accessories fluid valve High pressure valve CCV300 f N See f A e d s Ws E N 2 6 Vi 1 4 3 8 11 12 Serial Piece Name and finished DIN Material Comment no dimensions 1 1 End plate push fit fitting 14305 2K 4121 2 1 Adapter 14305 2K 4122 3 1 End plate G 1 4i 14305 2K 4123 4 O ring 10x 2 Viton 2K 4119 or 10x2Viton 2K 4119 FEP FEP sheathed 5 Hex socket screw M4 x 931 8 8 vz 2K 4125 40 6 Blanking plug 14305 2K 4126 7 Plug G
5. Page 40 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 m CODES 5 5 11 Security codes When delivered all menus are accessible without code input input 0 After installation and commissioning all security related settings should be password protected against unauthorised access Passwords are set in the same manner as any adjustment of the codes that may be required later To set a code first press the key icon shown above You will be asked to enter the master code which for reasons of security is not part of this documentation It will be sent separately to you from ITW Binks After entering the code press the field for which you want to secure the menu with a new password You will see the input mask new code Enter your new secret number here The code will be stored automatically If you should forget or mislay your access code you can also use this procedure to find out the stored code But keep the master code safe because it is an unchangeable part of the control software Page 41 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 Iro 5 5 12 Administrator settings This menu contains settings that should only be changed by service technicians You will be given the access code if required on request Adninistrator Zetting fester tind a flare Fluch em rec Gal ch Flurh MEN eein EEEN COH L boud ratt COH L funetion DRIVE Paud ratt 3500 WAD port
6. The stored value indicates the maximum interval between two hardener metering injections in millilitres Important this value has no effect on the quality of mixing It only serves a monitoring function The apparatus itself tries to meter the hardener in the smallest possible injections The cycle Page 30 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 frequency of the valve depends on hardener overpressure the needle stroke of the metering valve flow rate viscosity and many other factors Generally the increment size should be adjusted in such a way that mixing of the fluid in the mixer can just take place An increment size of 100 ml for a static mixer with a filling volume of 20 ml may have the result that the fluid will not be mixed accurately but that the apparatus continues to operate without any error signal Metering cell monitoring the value stored here indicates for how long the spray gun may be opened without the metering cell having to move Monitoring of the gun opening in manual installations is generally carried out by the air flow control integrated into the atomizing air For automatic installations this signal can also be given directly by an external control facility When the painter opens the gun the fluid flow should start shortly afterwards and activate the gear wheels of the metering sensors As long as a movement is recognised and impulses are thus sent by the metering cells to the mixing appar
7. 1 4i 14305 2K 4127 8 4 Clamping screw M5 x 16 912 8 8 vZ 2K 4128 IP1 31 9 4 Clamping screw M5 x 60 912 8 8 vZ 2K 4129 IP1 1x2 31 10 4 Clamping screw M5 x 100 912 8 8 vz 2K 4130 IP1 2x2 31 11 4 Clamping screw M5 x 140 912 8 8 vz 2K 4131 IP1 3x2 31 12 4 Spring washer A5 7980 2K 4132 13 O ring 10x 2 Viton 2K 4119 or 10 x 2 Viton 2K 4119 FEP FEP sheathed Page 64 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 2K 2027 Return valve 1 4 BSP gt M16x1 5 2K 2029 Colour change stack 2 2 until 2007 2K 2030 Colour change stack 4 2 2K 2031 Colour change stack 6 2 until 2007 2K 2032 Fitting 1 4 BSP gt M16x1 5 Page 65 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 2K 2033 Screw plug 1 4 BSP short version for colour change stack 2K 2034 Disc washer stainless steel for colour change stack until 2007 2K 2035 Adapter for high pressure valve on colour change stack until 2007 2K 2036 Seal 1 4 aluminium Page 66 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 51410L14 Adapter adjustable 1 4 BSP gt M16x1 5 2K 2160 Adjustable T screw connection M16x1 5 2K 2038 Adjustable L screw connection M16x1 5 Page 67 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 8 4 6 Touch panel TOUCH PANEL
8. 8 x 3 way 2 position valves Solenoid valve 5 way 2 position with coil 24 VDC and cable Magic Flow integrated gauge 0 10 bar 40 mm front mounting Magic Flow air regulator 3 8 air regulator range of adjustment 0 10 bar Merchandise Group Fluid Part Magic Flow 2K 2015 2K 2016 2K 2017 2K 2018 2K 2019 2K 2020 2K 2021 2K 2084 2K 2068 Magic Flow volumeter Volumeter stainless steel 1 4 F P max 250 bar metering range 50 2000ml min slide bearing Magic Flow single pickup Pickup for volumeter not EEx proof connection M12 four conductor Magic Flow single pickup EEx Pickup for volumeter EEx proof connection M12 four conductor Section switch amplifier Section switch amplifier for volumeter 1 channel design for top hat Pair of Magic Flow gear wheels Pair of gear wheels incl slide bearing bush ca 8 800 pulses litre Magic Flow shaft volumeter Volumeter connection cable with plug 5m yellow Volumeter cable sold by metre colour yellow Volumeter cable sold by metre colour blue Merchandise Group Options Magic Flow 2K 2006 2K 2007 2K 2008 1 Magic Flow EEx proof kit Conversion kit for Magic Flow includes 2 x EEx sensors for volumeter in exchange for standard sensors 1 x EEx solenoid valve 5m cable 2 x section switch amplifiers Robot communication kit 8 x optoelectronic coupler inputs 8 x optoelectronic coupler outputs In top hat housi
9. Flow Rev 3 0 Software release 02 2011 Personal notes Page 73 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 ITW Industrial Finishing IT WOberflachentechnik GmbH Ringwood Road Bournemouth Justus von Liebig Str 31 BH11 9LH England D 63128 Dietzenbach Tel 44 0 12 02 57 11 11 Tel 49 0 60 74 403 1 Fax 44 0 12 02 57 34 88 Fax 49 0 60 74 403 300 E mail industrial mktg itwfinishing co uk E mail marketing itwifeuro com ITWSurfaces et Finitions 163 171 Av des Aureats 26014 Valence Cedex FRANCE Tel 33 4 75 75 27 00 Fax 33 4 75 75 27 59 E mail mkt itwsf com www itweuropeanfinishing com Page 74 of 74 Feb 2011
10. determined by the greatest share of the total mixture and permanently opened while the other components will be added by metering Only enter values under C if the apparatus is also equipped as a 3C installation Ensure that the valve numbers entered are actually connected to the relevant metering cells Page 24 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 Adjust the pot life of the relevant mixture under t min in minutes If an automatic pressure adjustment kit optional is connected to the apparatus you can determine the fluid pressure under p bar which will be adjusted after filling Under Flush enter the flushing program that should be assigned to this recipe You can select one of the ten flushing programs that you set up earlier Under Active you can determine whether it is an active recipe that can be started immediately You can release recipes to the operator or block them in this way Inactive recipes will flash when they are selected in the main menu and cannot be used The icon with the crossed out disk rejects all modifications and downloads all 50 recipes again from the system memory The icon with the disk stores all modifications and takes you back to the tool menu ATTENTION both when aborting and saving the control unit requires a few seconds either to write the data of 50 recipes to the EEprom or to read them from the EEprom For this reason do not try UNDER ANY CIRCUMSTANCES to sp
11. repair to be carried out at your site please note that you will be charged for any travel costs that may be incurred The warranty is rendered invalid if any malfunctions or defects occurring were caused by improper use or operation of the apparatus or due to the accessing of assemblies for which access was not authorised Page 5 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 The warranty does not cover wearing parts that have been subjected to normal wear These include e g gaskets packings and nozzles The warranty period will be twelve months in one shift operation and six months in two shift and three shift operation starting from the date of initial operation but at the latest 30 days after delivery Any other agreements must be drawn up in writing Page 6 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 2 General 2 1 Notes for the user The safety precautions and safety standards in this section have been compiled for your safety and in your interest For safe operation it is necessary that the user reads and understands all of the technical and safety literature and acts in accordance with it The user must be familiar with the function of the apparatus and must be aware of the hazards and risks that may occur with pressurised pumps hoses and equipment 2 2 General safety standards DO NOT move operate maintain or service the apparatus before you have read and understood this se
12. the mixing process is called up via a remote control or a robot communication module the last selected gun combination will be automatically applied again Page 44 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 5 5 13 2 Control of agitators If the option for control of up to sixteen agitators is connected to the system these can be programmed as follows The function of each agitator can be tested in the programming menu All agitators can be set individually and independently of one another to OFF LOW HIGH LOW and HIGH each describe just one digital output Assigning these outputs to electric motors or solenoid valves is down to the user The outputs can also be used to repump fluid in circulation etc The values of LOW OFF and LOW ON describe the cyclical turning on and off of the relevant outputs regardless of the operating mode of the apparatus The HIGH ON time shows the time taken to turn on the relevant output before the start of the mixing procedure LOW OFF TIME indicates how many seconds the output is turned off for LOW ON TIME indicates how many seconds the output is turned on for All agitators are always turned on and off at the same time Example LOW OFF 3000sec LOW ON 600sec All agitators are turned on for 10 minutes and off for 50 minutes every hour Page 45 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 HIGH ON the mixing process is started with one compone
13. valves 1 to 4 You can test the optionally available pressure adjustment kit using the analogue regulator With you reduce the value by 0 1 bar with you increase the value by Page 28 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 0 1 bar With Analogue OFF you reset the value to 0 0 bar The kit performs adjustments from 0 0 to 7 0 bar Page 29 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 oe Important security related settings for the operation of the apparatus can be entered in the system settings The correct setting of these parameters is of great importance for the resulting finish and trouble free operation of the apparatus 5 5 4 System settings Deeg Sc a Filling in ml DEUTSCH ENGLISH hEDERLAN DS F LSKI Filling im ml Filling quantity on the one hand the filling quantity is important for the external signal Filling to which e g a signal light can be connected which indicates to the operator that the filling procedure is not yet complete On the other hand the filling quantity is needed to monitor the pot life After the removal of twice the filling quantity the pot life will be reset to the start value Removal of twice the filling quantity is necessary to prevent mixing of already reacting and fresh fluid in the apparatus and in the hoses JL TT K Increment size the increment size is necessary for monitoring the accurate mixing of the fluid
14. you wish to change this value e g after changing to another volumeter you can do so by pressing the number input icon S 5 5 5 2 Determining K factors To increase the accuracy of the mixing apparatus it is recommended that all media be calibrated To do this proceed as follows u Press the icon with the mixing cup LES Page 33 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 Select the volumeter that is to be calibrated S 3 Select the valve that is to be used for calibrating P Page 34 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 Carry out metering The bar on the left side indicates the flow rate If the bar does not expand upwards when removing fluid you have either selected a valve which is not allocated to the selected volumeter or the metering cell is mechanically blocked The number top right indicates the number of pulses First open the spray gun and remove fluid The pulse counter must now display an increasing value Using the START RESET key you can reset the pulse counter to zero After filling the system with fluid press the key wait for a few seconds and then start the actual metering Remove an easily readable quantity of fluid into a metering cup Then close the spray gun and wait for a few seconds until the pulse counter has come to a stop Finally press the OK key You will then be asked to ent
15. ADJUSTMENT The touch panel is adjusted on delivery and can be used immediately Due to aging and wear it may be necessary to readjust the touch panel Adjustment procedure 1 On switching on touch panel and keep it depressed When the following message appears touch adjustment you can stop touching the panel 2 Within one second touch the panel again for at least one second 3 Follow the instructions for the adjustment touch the two points on the top left and bottom right corner of the panel The touch panel can be obtained by quoting item number 2K 2052 Alternatively a replacement display can be obtained by quoting item no 2K 2052 REP in case of e g glass breakage Page 68 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 9 Decommissioning apparatus If the apparatus is to be shut down for a prolonged period of time the following steps must be carried out 1 Carry out at least one complete flushing procedure in order to remove mixed fluid from the apparatus Depressurise all fluid supply systems Open all connected valves manually via the relevant menu in order to relieve residual pressure Remove all supply hoses from the colour change valves Connect the flushing agent supply system to each valve in succession open the valve manually and flush it via the gun or via a hose connected to the outlet Remove the flushing agent supply system Fill each valve with a few millilitres of pr
16. Function ist pat Life alara Stop after Filling pot Lift factor ACCESS TIME the time shown in seconds indicates that in apparatus with a robot communications kit for which it is assumed that these are operated via external control access via touchscreen must be confirmed once more within the time indicated to prevent mistaken commands ALARM FLUSH time after which a flushing process is triggered automatically in case of an alarm 0 sec no forced flushing COL Ch FLUSH indicates whether automatic interim flushing takes place OFF no interim flushing RECIPE changing recipe 1C 2C 3C only when changing paint type thus from 1C to 2C paint COM 1 BAUD RATE speed of serial interface The value must be set to 57 600 for the optional Ethernet interface For serial printers 19 200 Baud is normally used COM 1 FUNCTION printer data that are output on a printer are printed automatically Web server data are only output on request strictly according to communications protocol Screenshot the receipt of any byte results in the return Page 42 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 of the screen contents in an internal format The data must be received with a special tool and converted into a bitmap bmp COM 2 BAUD RATE see above only relevant if there is an optional second interface D A PORT FUNCTION function of analogue output 0 7bar pressure adjustment kit 0 1 0l min the cu
17. If the icon flashes the Page 16 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 apparatus has not yet been cleaned after the last mixing procedure and the remaining pot life will continue to be counted down The pot life will only be reset to the start value after a flushing procedure has been CARRIED OUT IN FULL The flushing program activated by the last mixing procedure will always be selected by default It is not important therefore which flushing program number is displayed on the icon but which recipe was started and stopped last 5 2 4 Enter settings R This icon will take you to the system settings Here you can change recipes operating parameters and safety settings for example Depending on the setting the various sections may only be accessed using passwords Page 17 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 5 3 Painting mixing During the mixing procedure four different displays can be selected By using the arrow keys on the bottom of the screen you can change between the displays GH 1 The set values of the mixture ratio and the selected valves are displayed in the top line in all displays 2 Below this you can read the current actual values The measured value for each component is displayed in millilitres and in percent 3 You can read the total consumption at this position This is important for example for the filling quantity of the syst
18. Magic Flow Rev 3 0 Software release 02 2011 Operating instructions Magic Flow LOW 2 s nKS MABIL by Page 1 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 Table of contents 1 Identification data 1 1 Preface 1 2 Identification of the apparatus 1 3 Warranty 2 General 2 1 Notes for the user 2 2 General safety standards 2 3 Reaction hazard 2 4 Fire and explosion hazard 2 5 Toxic solvents 2 6 Injection hazard 2 7 Hazard posed by escaping liquids 2 8 Emergency shutdown 2 9 Residual pressure 3 Description of the system 3 1 Functional characteristics 3 2 Mixing 3 3 Fluid delivery 4 Installation 4 1 Transportation 4 2 Storage 4 3 Installation 4 4 Electrical connections 4 5 Motherboard with processor card 4 6 Pneumatic connections 4 7 Solenoid valve terminal 4 8 Fluid hose connections 5 Operating the system 5 1 General 5 1 1 Turning on the apparatus 5 1 2 Numerical input 5 2 Main menu 5 2 1 Select recipe 5 2 2 Start spraying procedure 5 2 3 Start flushing procedure 5 2 4 Enter settings 5 3 Painting mixing 5 4 Flushing 5 5 Settings 5 5 1 Recipes 5 5 2 Management of flushing 5 5 3 Valves 5 5 4 System settings 5 5 5 Calibrate adjust K factors 5 5 5 1 Manual adjustment of K factors 5 5 5 2 Determine K factors 5 5 6 Container monitoring Page 2 of 74 Page 5 Page 5 Page 5 Page 7 Page 7 Page 8 Page 8 Page 8 Page 8 Page 9
19. OB The consumption of the component and its VOC content is listed both at the total consumption meter and at the job meter The relative VOC content in percent can be set in the VOC Menu see 5 5 9 Press the key PRINT ALL in order to print the consumption values of all components if the optional printer is connected Page 38 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 VO 5 5 9 V O C values S EW EBEZEZESIEZEZEZ EA fie EEE iz iz is 15 ie Peel PE BEI EN PE EH ras se st a2 Ho aoe Hl 11 0 s Press the keys 1 to 32 to select the valve and component respectively for which you wish to adjust the VOC value The VOC value in will be displayed in the centre Press the key V O C to adjust the value for each valve separately The value is needed in order to calculate not only the consumption but also the VOC emissions for the consumption reports Page 39 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 ALARM EVENTS 5 5 10 Alarm memory P The mixing apparatus stores up to 100 alarm messages in order of appearance You can browse the alarm history with the keys and gt If more than 100 errors were recorded the last 100 messages are still available Each alarm message is listed with date and time as well as the reason for the alarm You will find the meaning of the alarm icons in the chapter Alarm Messages
20. Page 9 Page 9 Page 10 Page 10 Page 10 Page 11 Page 11 Page 11 Page 11 Page 12 Page 13 Page 13 Page 14 Page 15 Page 15 Page 15 Page 16 Page 16 Page 16 Page 17 Page 17 Page 18 Page 21 Page 23 Page 24 Page 26 Page 28 Page 30 Page 33 Page 33 Page 33 Page 36 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 5 5 7 Printer configuration 5 5 8 Reports 5 5 9 V O C values 5 5 10 Alarm memory 5 5 11 Security codes 5 5 12 Administrator settings 5 5 13 Optional software 5 5 13 1 Control of flushing pockets 5 5 13 2 Control of agitators 6 Maintenance 6 1 Cleaning and maintenance of the fluid handling section 6 1 1 Cleaning of hoses and tubes 6 1 2 Maintenance of valves 6 1 3 Maintenance of metering cells 6 2 Cleaning of control module 7 Alarm messages and troubleshooting 8 Spare parts and options 8 1 Spare parts and options in general 8 2 Control components 8 3 Components of a typical low pressure fluid handling section 8 4 Assemblies with spare parts lists 8 4 1 Fluid valve 2K 4002 high pressure 8 2 3 Fluid valve CCV 403 SS E low pressure 8 4 3 Volumeter 8 4 4 Air flow control 8 2 6 Accessories fluid valve 8 4 6 Touch panel 9 Decommissioning the apparatus 10 Annex 10 1 Flow chart 10 2 Connecting fluid handling section and electrical cabinet 10 3 Technical characteristics Personal notes Page 3 of 74 Page 37 Page 38 Page 39 Page 40 Page 41 Page 42 Page 44 P
21. age 44 Page 45 Page 47 Page 47 Page 47 Page 47 Page 48 Page 49 Page 52 Page 52 Page 54 Page 55 Page 56 Page 56 Page 58 Page 60 Page 62 Page 63 Page 67 Page 68 Page 69 Page 70 Page 71 Page 72 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 EC Declaration of Conformity in accordance with EC Directives Machinery 93 68 EEC Annex II B Electromagnetic Compatibility 89 336 EEC amended by 92 31 EEC Low Voltage 73 23 EEC The installation machine Function Electronic 2 or 3 component mixing and metering system Trade name Magic Flow Type designation 2K 2000 has been developed designed and manufactured in accordance with the above Directives The following harmonised standards were applied DIN 60204 1 ZH 1 406 ZH 1 200 EN 50082 2 1993 EN 50082 2 1995 Manufacturer ITW Oberflachentechnik GmbH amp Co KG Justus von Liebig Str 31 63218 Dietzenbach Germany Andr de Neergaard Managing Director Page 4 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 1 Identification data 1 Introduction 1 1 Preface Dear Customer Congratulations on the purchase of your new electronic multi component apparatus Please be assured that design and fabrication of the apparatus have been carried out according to the state of the art and with the aim of maximum user convenience and the highest safety level based on the selection of the best materials
22. as per DIN ISO Ma stab Scale Materialventil Material valve Ersatz f r Replacement for Diese Zeichnung wurde mit CAD erstellt und mu mit CAD ge ndert werden This drawing was produced using CAD and must be amended using CAD Page 56 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 Item Quantity Unit Name Standard code Comment designation l 1 Piece Valve body 2K 4100 2 1 Piece Air cylinder 2K 4101 3 1 Piece Cap 2K 4102 4 1 Piece Piston 2K 4103 5 1 Piece Nut 2K 4104 6 2 Piece Spacer 2K 4105 7 1 Piece Packing holder 2K 4106 8 4 Piece Socket head cap screw M4 x 40 DIN 912 8 8 vz 2K 4107 9 1 Piece Sealing ring 12x 16x 1 5 2K 4108 10 2 Piece Sealing ring 14x 18x 1 5 2K 4109 11 1 Piece Fastening screw G Ya 2K 4110 12 1 Piece Compression spring 2K 4111 13 1 Piece Compression spring 2K 4112 14 1 Piece O ring 25 3 x 2 4 2K 4113 15 1 Piece O ring 3 3 x 2 4 2K 4114 16 17 1 Piece Seal kit 3xsleeve graphite 2K 4115 coated 3xO ring Viton 3xsleeve PTFE Seal kit recommended for 3xO Ring Viton 2K 4115 1 hardener valve 18 1 Piece Valve needle 2K 4116 21 1 Piece Locking piece with valve seat 11 16 x 16 UN 2K 4117 27 1 Piece Screw plug G 1 4 2K 4118 28 1 Piece O ring 10 x 2 Viton 2K 4119 or 10 x 2 Viton 2K 4119 FEP FEP sheathed 29 4 Piece Spring washer 4A DIN 7980 vz 2K 4120 Page 57 o
23. atus controller monitoring of the metering cells is reset However if a metering cell is blocked because of contamination for example so that it can no longer detect a volume flow the apparatus will emit an alarm signal after the time set here The time should be in the range of 5 10 seconds in order to ensure that no unmixed fluid can escape from the gun The time chosen should not be too short less than 3 seconds however since the painter occasionally uses the gun to blow dust from the object to be coated SET CLOCK Time press the SET CLOCK key in order to set the internal clock of the apparatus The clock has a power reserve of approximately 10 14 days The clock is necessary to print logs and for storing alarm messages To change values press the keys To store the modifications press the OK key Display brightness enter the value for the relative display brightness in percent 0 100 Please note if the value is too low you might not be able to read the displays and will then not be able to increase the value Z Standby time the standby time in seconds indicates the time period after which the display turns off to extend the service life of the lighting cathode The apparatus only switches to standby mode if it is flushed and if it is in main menu mode all valves closed Page 31 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 If the apparatus is in standby mode it is sufficient to to
24. component pressure resistant up to 10 bar LP or 250 bar HP incl 1 static mixer Stand post aluminium profile construction for 2 C apparatus height 1500 mm depth 400 mm control cabinets can be mounted with height adjustment Wheels set 2 x castors 75 mm antistatic 2 x castors antistatic with double lock up brake completely mounted Merchandise Group Electronic Magic Flow 2K 3004 1 2K 3004 2 2K 3004 3 2K 3004 5 2K 2049 2K 2073 2K 3050 2K 2051 2K 2052 2K 2064 Expansion module for valves 9 16 for fitting on top hat rail Expansion module for valves 17 24 for fitting on top hat rail Expansion module for displaying filling levels of 8 containers Minimum value check Expansion module for control of up to 4 gun extractor units Switching power supply 230VAC 24VDC 3 2A 75W top hat mounted Line safety switch characteristics B16 Motherboard supplied without display or processor card Processor for motherboard chip set Siemens Infineon C1144 pre programmed Touchscreen LCD display with analogue touch field 240 x 128 pixels CFL lighting blue white pre programmed for Magic Flow Air flow control adjustable air connections 3 82 F 24 V power supply signal output 24V PNP switching Page 52 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 Merchandise Group Spare Parts Magic Flow 2K 3011 2K 3012 2K 2071 2K 2070 Solenoid valve terminal 24 VDC with
25. ction of the metering sensors will be monitored on the one hand and on the other hand the apparatus will be shut down and an alarm triggered if the required mixture ratio has not been achieved e g insufficient material Due to the high precision of the mixing and the controlled and economic handling of solvents and paint materials the electronic mixing and metering equipment is clearly superior to mechanical metering equipment in many respects 3 2 Mixing The apparatus regulates and injects the B component optionally also C into the running volume flow of side A To obtain a good mixing result it is necessary to connect a static mixer to the outlet of the apparatus Care must be taken that the static mixer complies with the maximum pressure of the complete installation The length of the mixer the number of mix steps and the diameter are determined by the paint material used the mixture ratio and the maximum volume flow It may be necessary to insert a downstream hose mixer e g at very high flow rates 3 3 Fluid delivery The fluid can be delivered either by piston pumps double and mono diaphragm pumps or by pressure tanks Care must be taken that all components are operating in a similar pressure range So combined operation with e g pressure tanks and high ratio piston pumps is not recommended It must be ensured that the components of side B possibly also of side C have a pressure that is approximately 10 higher than sid
26. d in order to ensure that every gun is flushed properly Page 22 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 5 5 Settings All installation parameters can be set in the tool menu All settings can influence the mixing result and should therefore only be carried out by trained personnel or by service technicians The option also exists of protecting all sub menus by passwords and of informing only selected persons of these see Security codes Page 23 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 5 5 1 Recipes Press the recipe key to access recipe administration if necessary enter security Press the key at the top left hand side for the recipe number to select the recipe to be edited In the centre of the screen you can choose any name for the recipe with up to 15 characters This name will be displayed in the main menu under the recipe number This will make it easier for you to assign the recipes to the associated colours In the table top right a fluid valve can be allocated to each metering channel A B C for the selected recipe and the fluid ratios for the recipe can be determined Please note that the volumetric mixture ratio will be entered It is of no importance whether for example for A 4 portions and for B 1 portion are entered or whether the mixture ratio will be entered e g as 100 25 During the mixing procedure the main component will automatically be
27. e A in order to be metered and fed in For proper operation of the apparatus the following are the minimum requirements apaint supply for side A ahardener supply for side B asupply of flushing agent two are possible depending on the paint system If necessary a supply of thinners for 3C installations Page 10 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 4 Installation 4 1 Transportation Depending on the design the apparatus consists of one or two modules which can be transported separately from each other Transportation will be on pallets Two people are needed to handle them 4 2 Storage If the apparatus is to be stored the control section must be protected against heat and humidity In order to avoid condensation the apparatus must not be exposed to substantial temperature changes otherwise the apparatus must be exposed to the new ambient temperature with flaps open for several hours prior to operation The fluid handling section is extensively resistant to external influences For a longer period of storage however it should be filled with preservative oil in order to take care of the packings and to guarantee smooth operation With regard to the supply pumps proceed according to the relevant service manuals for the pumps 4 3 Installation Industrial installations from ITW are normally commissioned by the company s own service technicians or our agents service technicians Th
28. eed up this process by pressing especially hard on the display Page 25 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 5 5 2 Management of flushing Press the flushing program key to access management of the flushing process if necessary enter security code First you are asked to enter the number of the flushing program that you wish to edit You can enter the numbers 1 to 10 P AUT Lalue Dinension Dume Loop Humber of Eng Loops 1 Current flushing step that is being processed a flushing procedure may consist of up to 20 different steps Only those flushing steps for which values are stored are run in numerical order 2a 2b Flushing step forward flushing step back changes to previous or next flushing step that is to be processed 3 Valve number number of the flushing valve which is to be opened in this step 4 Flushing value set point value of this step which must be processed so that the apparatus skips to the next step optionally in ml or in sec see 4 5 Dimension displays whether the current flushing step will be carried out in millilitres or in seconds In principle cleaning of the apparatus in millilitres is a more reliable process However quantity recording is not sensible for steps which cause air solvent flushing for example So the dimension can be determined separately for each flushing step Page 26 of 74 Feb 2011 Magic Flow Rev 3 0 Soft
29. eichn Nr Valve Bod 16 1 Schaltanzeiger CCV 42 Valve Indicator 17 1 Ventilkappe CCV 43 Valve Cap Klebstoff mittlerer Festigkeit Loctite 242 Leichtes Schmierfett Light grease 7 Bemerkungen Remarks Supplier An 2 Stellen auf Gewinde auftragen Use on threads 2 places Bei Montage d nnen Film auf Bohrung und Manschette auftragen Apply a thin film of lubricant to bore amp cup at assembly a Ring Retainer In Reparatursatz KK 4841 enthalten Supplied in Repair Kit KK 4841 Page 59 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 8 4 3 Volumeter 2K 2015 Einzeloufnehmer Volumensensor VHMO2 1 2516 2 Einzelaufnehmer 23 149 wahlweise Sitz des Einzelaufnehmers 7 nach Datum Name Benennung 20 4 05 IS Volumensensor VHM02 1 2S16 2 DE Mer Signalaufnehmer V 2 50 D Auslass E Lie test 4 5 05 Zeichnungsnummer Blatt b Hantar ars 3 5 05 Ot VSE GmbH V05 109 3c a_ Anspiegelg gein 21 4 09 Ot D 58809 Neuenrade Zust Anderung Datum Urheberschutz DIN 34 Ers t V05 109 3b Ers d 55 peu n N 60B85 HIWD ISA M12x1 N OOSZ A d L 25 104 Yerwendungsbereich Ansicht X Anschlu bild Mahe o Tole ranzangabe Single pickup Mafstab 1 1 Werkstoff Halbzeug
30. ell cables according to the wiring diagram supplied Take care to ensure that channels A B and if present C are correctly assigned Earth both the control cabinet and the fluid handling cabinet according to the relevant regulations Page 71 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 10 3 Technical characteristics General characteristics Type of protection of the control part IP 52 Type of protection of the fluid handling part EEx proof for operation in EEx Class 2 optional EEx proof for operation in EEx Class 1 Materials for parts in contact with fluids Stainless steel PTFE polyamide Special characteristics Software Freely adjustable recipes 50 Triggerable components 32 Storable parameters No A amp B amp C mix ratio pot life optional fluid pressure Adjustable flushing parameters 10 flushing sequences 20 steps each with valve number quantity or time dump valve Storage of details of consumption of all components Mixture ratio 0 200 metering relative to main component 100 Hardware Mixing accuracy better than 1 according to calibration Volume flow according to design standard 0 05 2 l min per channel Maximum working pressure 10 bar standard version optionally up to 250 bar versions with higher pressure are available on request Measurements Height 1750 mm incl castors and legs Width 640 mm Depth 400 mm Page 72 of 74 Feb 2011 Magic
31. em or for resetting the pot life 4 Remaining pot life The basic pot life is stored in the recipe If not enough fluid is extracted the pot life will run towards 00 00 00 and will subsequently set off an alarm If the alarm is not acknowledged in time within 5 minutes an automatic flushing procedure will be started IMPORTANT In order to reset the pot life automatically double the amount of the paint filling quantity has to be extracted from the system in order to ensure complete fluid replacement Example If the filling quantity is determined to be 200 ml and this is stored in the system system settings the pot life will always be reset to the initial value after the removal of 400 ml 5 Using the arrow key will take you to the previous display 6 Pressing the Stop key ends the mixing procedure 7 Using the arrow key will take you to the next display Page 18 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 strokes nou 8 strokes total z i STOP en 1 strokes now the total number of strokes of the fluid valves in this recipe since the start of the mixing procedure The main component stays at 0 because the valve is only opened at the start and closed at the end The number of strokes per volume provides information about the quality of the dosing Many small hardener injections result in a better mixing result than a few large injections 2 strokes total total number of
32. ently regular checking of the valves is indispensable Servicing of valves at regular intervals is recommended once initial empirical values have been obtained You will find further details in Annex 10 5 6 1 3 Maintenance of metering cells In principle our metering cells are maintenance free If it should be necessary to clean blocked metering cells however please note Metering cells have to be handled according to the manufacturer s instructions see annex 10 4 The accuracy of the metering cells must be checked at regular intervals calibration because the use of abrasive or pigmented media will cause wear which affects the accuracy of the gear wheels Page 47 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 6 2 Cleaning of control module The control module must only be cleaned with mild cleaning agents There are no internal components or assembly groups which need cleaning or maintenance Cleaning the touchscreen display with solvents is not allowed If you are concerned about extensive contamination of the display slightly self adhesive transparent protective films are available which can easily be replaced Page 48 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 7 Alarm messages and troubleshooting Fault Possible cause Remedy Alarm message no volume flow A side Atomizing air is open without spraying Set longer activating time for meterin
33. er the volume of the fluid removed The resulting K factor will be displayed and will then be entered into the system Page 35 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 ACTUAL COMTEMT Integrated container monitoring serves to check the container levels without any additional sensor systems If a container is to be monitored its level must be stored in this menu prior to use Starting from the consumed quantity of fluid metered the system can emit an alarm signal if a defined minimum level is reached in order to avoid no load operation of the pumps with resultant defective mixtures and operating failures The container that is to be set or monitored is selected using the buttons 1 32 The container size present when delivered is set using the button MAX LEVEL ACTUAL CONTENT displays the current container level Press the button to refill the container numerically or to enter any new level MIN LEVEL displays the minimum level An alarm signal will be triggered if the level falls below this value Press the button to adjust the level ACTIVE and NOT ACTIVE indicate whether monitoring is to be activated If the button is in ACTIVE mode an alarm signal is emitted If the button is in NOT ACTIVE mode the container level will be calculated but the minimum level will be ignored Page 36 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 5 5 7 Printer confi
34. eservative agent and close it with a screw plug Remove the electrical and pneumatic supply connections Store the apparatus in a dry place Page 69 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 10 Annex 10 1 Flow chart Components L semittel Solvent Kompenten usjusuoduoy g Teqqtuesel 8 Te4q4tusesgy Y us2usuoduoM y use E Legend Q E 53 EK S 5 Q Ei Q Ka Es 3 D Ss 2 S E 8 D o Q ZG m E o lt T N oa man gt mz OO n x be oO 0 co gt SS ef 8 Ko Leift ka D D D e d E vrc Loxe O 5 SS e SUE e koj og Ee wi H SE a ZE oz EIZ 022358 oooD oe DU OoOOp oo e ON ost OO oOt OD Feb 2011 Page 70 of 74 Magic Flow Rev 3 0 Software release 02 2011 10 2 Connecting fluid handling section and electrical cabinet The fluid handling cabinet and control cabinet are delivered separately in the basic version Following mechanical assembly air and cable connections must be created between the two separate units Proceed as follows 1 Connect the air outlet of the electrical control cabinet to the air inlet of the fluid cabinet 10 mm air hose Connect the air hoses for activating the fluid valves 4 mm outer diameter Connect the metering c
35. f 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 8 4 2 Fluid valve CCV 403 SS E low pressure 13 12 10 n 9 14 157 6 5 4 A 2 SEZA U EINS FY RA Re il E eg KTS T RONG gt nN MRS IN Sch f camp _ gt 17 18 19 101 Qty Description Part No Draw No Remarks Supplier Steueriufteingang 1 8 NPT F Air Inlet 1 8 NPT F Haltemutter CCV 45 Clamping Nut Manschette A 246 Cup Mutter CCV 3 Nut Druckfeder CCV 41 Spring Druckscheibe CCV 4 Spring Washer Nadeldichtung CCV 8 Valve Needle Seal Material Einla 2 fach NPT F Fluid Inlet 2 ports E Schraubenh lse CCV 13 Spanner Nut Sprengring SST 8436 Retaining Ring Ring CCV 44 Ring Retainer Ventilsitz CCV 40 Poppet Seat Ventilnadel CCV 39 Stem Blindstopfen SSP 1421 Pipe Plug In Reparatursatz KK 4841 enthalten Supplied in Repair Kit KK 4841 Ersatzteilsatz CCV 41 K2 Spare Part Kit CCV 41 K2 Ersatzteilsatz CCV 8 K2 Spare Part Kit CCV 8 K2 Ersatzteilsatz SST 8436 K5 Spare Part Kit SST 8436 K5 Ersatzteilsatz CCV 40 K2 Spare Part Kit CCV 40 K2 Reparatursatz KK 4841 bestellen Order Repair Kit KK 4841 Wird mit Ventil lose mitgeliefert Nicht ben tigt bei Farbzirkulation Shipped loose with valve Not used if material is recirculated Page 58 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 LLVWv2 35 0 orci z z P Anz Benennung eile Nr
36. g cell monitoring Do not open atomizing air unnecessarily Tip clogged no fluid flow with gun open Clean tip replace if necessary Colour change valve connected to wrong solenoid valve no trigger air signal Check allocation of colour change valves to solenoid valves Colour change valve does not open although trigger air is applied Disassemble colour change valve clean replace seals see service manual for valve Lack of fluid Check fluid delivery system on A side empty container Defective feed pump Check functioning of pump see service manual of pump Blocked metering cell Start flushing procedure disassemble metering cell and clean if necessary Defective sensor on metering cell Contact service technician replace metering cell Cable rupture or wrongly connected Test cable replace if necessary Page 49 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 Fault Possible cause Remedy Alarm message no volume flow B or C side Atomizing air is open without spraying Set longer activating time for metering cell monitoring Do not open atomizing air unnecessarily Hardener pressure too low Set hardener pressure to pressure of main colour approximately 10 Tip clogged no fluid flow with gun open Clean tip replace if necessary Colour change valve connected to wrong
37. guration y UNIT ID Magicrlow af RENTING 1 OO PRINTING OK 7 AFTER sec wv UNIT ID displays the name of the mixing apparatus which appears on the print outs It is therefore possible to distinguish between the print outs of different apparatus The name can have up to 10 characters PRINTING AFTER ml displays the intervals at which process information is to be printed In the above case a print out would be started after the removal of one litre of fluid in each case PRINTING AFTER sec displays the time intervals at which a print out is to be printed during the mixing procedure It is possible to activate both print out variants but also only one or neither of them If no print outs are to be produced set both values to 0 Set the following parameters at the printer interface that is provided as standard serial Baud 9600 8 bit no parity 1 stop bit no hardware handshake Page 37 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 pa Reports Use the keys 1 to 32 to select the valve and component respectively where you wish to read the consumption TOTAL displays the total consumption of the component since installation of the system It is not possible to reset this value JOB displays the consumption since the last reset of this value It is possible to record weekly consumption for example The operator can reset these values using the key RESET J
38. ibilities Only fill with tip 7 d KA DIE Mixing tolerance A B C exceeded only for Pressure differences too high added components enter mixture with too great an injection gt Recognisable from pulsing Slowly reduce hardener pressure reduce needle stroke at metering valve Uneven operation of feed pumps Check pumps clean and replace packings if necessary Increment size selected too small Adjust increment size within the possibilities Flow rate too high for example by filling without Adjust increment size within the possibilities components that are spray tip Only fill with tip added Fault Possible cause Remedy Alarm message Pot life expired Apparatus has not been flushed in good time Start flushing procedure Insufficient fluid removed from apparatus within pot life period Start flushing procedure Page 51 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 8 Spare Parts and Options 8 1 Spare parts and general options Item No Description Merchandise Group Basic Installations Magic Flow 2K 2000 2K 2001 2K 2002 Magic Flow electronic 2 component mixing and metering apparatus electronic control cabinet 600 x 380 x 350 mm with touchscreen pneumatic hydraulic control cabinet 600 x 700 x 210 mm equipped for 1 main colour 1 hardener 2 flushing agents metering range 50 2000 ml min per
39. is is to avoid faults at the very beginning caused by defective installation or operation If installation is not to be carried out by an ITW service technician please check the completeness and the correct function of all components within the scope of delivery When installing always take into account the operability of the installation the ambient conditions e g EEx explosion proofing and the safety of operators ATTENTION the control cabinet cannot be located in the EEx area If operation in the EEx area is necessary a remote control panel is available as an option 4 4 Electrical connections The apparatus will be supplied via a central electrical input at the control cabinet Pay attention to proper earthing of the necessary shock proof plug In the basic version the fluid cabinet fluid handling section and the electrical cabinet will be delivered separately The connection of the two parts should be carried out according to the description in section 10 2 Connecting fluid handling section and electrical cabinet Page 11 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 4 5 Motherboard with processor card GND P1L 0 PiL 1 P1L 2 Va AD 0 0 10 GND GND PiL 4 PiL5 P1H 7 24 Yin PIL H GND PAL x x 24V wi Count 3 Count 2 Count gt Count O GND Int P1H 5 V1 V8 N SCL SDA DM GND GND 24 II E eg Sei 5 WS Key for symbols Outputs for control
40. k discharge all components must be electrically connected to each other and earthed Use suitable clamps and clean the contact parts of spray mist if necessary Connect the clamps via suitable cable to an adequate earth potential permanently installed tubes etc If electrostatic charging still occurs check for proper earthing 2 5 Toxic solvent vapours etc Toxic and harmful vapours may be released by the spraying and misting of paints and other materials Follow all the manufacturer s safety instructions Keep to the relevant lower toxic limit values and maintain adequate ventilation 2 6 Injection hazard Never let any part of the body come in contact with the tip of the spray gun Never aim high pressure spray guns at any part of the body or at other persons under any circumstances Ifthe pressure is high enough the spray jet from high pressure spray guns can penetrate the skin Such an injection of liquid can have serious health consequences If such an incident occurs in spite of all safety precautions seek medical care immediately and inform the doctor of the nature and composition of the fluid that has penetrated see safety data sheets 2 7 Hazard caused by escaping liquids Never modify the connections of the apparatus without prior consultation Regularly check the condition of hoses and connections Take care that hoses are not crushed and bent below the permitted radius Never subject hoses and connections to high
41. mechanical loads in excess of those for which they are rated Replace damaged hoses immediately Check that all connections are tight prior to operation Page 8 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 Never try to stop or deflect leaking fluid with your hands or other parts of the body 2 8 Emergency shutdown In case of an accident or a hazardous situation turn the main switch to the OFF position This will render all components on the panel currentless and will close all valves 2 9 Residual pressure Even after interruption of the air supply to the pumps the lines fed by the pumps are still not depressurised as pressure can usually only be relieved in one direction In order to depressurise the complete installation open the spray gun and the relevant valves via the control device if no relief device is installed at the pumps Page 9 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 3 Description of the system 3 1 Functional characteristics The system is designed to meter two or three volume flows in which the main volume flow generally the main component will be opened and all other components e g the hardener will be regulated on basis of the metered first volume flow according to the mixture ratio of the chosen recipe All parameters and tolerance values that are necessary for the calculations will be filed in the system settings In order to guarantee maximum safety the fun
42. ng So the dimension can be determined for each flushing step separately see flushing programming 6 Dump valve for each step in the flushing program it is possible to set whether the signal Dump valve is to be activated The signal can then be used to activate e g a gun cleaning box or whether the cleaning is to be carried out via an external dump valve drain valve 7 Loop start if a loop was programmed in the flushing program which carries out certain steps cyclically for a certain number of repeats then the first flushing step of this loop can be displayed here Page 21 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 8 Last step of the loop described under 7 9 Number of loop run throughs see 6 Ka 10 This key interrupts the flushing procedure and closes all valves ATTENTION if the flushing procedure is interrupted the apparatus is regarded as still being filled The pot life continues to run accordingly For the refilling and flushing of several guns an output module is available You can connect up to 4 dump valves or gun extractor units If the system recognises this module during switch on the operator will be prompted on start up of the spraying process to enter the spray guns that should be activated If the system is flushed at a later stage the flushing procedure entered is run in full once for every previously filled gun During each run another extractor unit is activate
43. ng for connection to PLC bus cable length max approx 1m Magic Flow transceiver unit for PLC bus without cable for the connection of external PLC modules for a distance of more than one metre Recommended cable for connecting the units CAT5 CAT6 network cable twisted pair shielded Page 53 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 2K 3008 Top hat rail transceiver 2K 3026 Remote control non Ex with recipe display also required 1 x Transceiver Kit 2K 2008 1 and 1 x top hat rail transceiver 2K 3008 Remote control Ex Category 2 with recipe display also required 1 x 2K 3047 Transceiver Kit 2K 2008 1 and 1 x top hat rail transceiver Pneumatic remote control for Magic Flow 3 functions Start Stop Flushing 2K 2010 3 x P E converters and 3 x pneumatic buttons 2K 2072 Magic Flow isolated assembly 2 x metering cells Dual pick up for metering cell with fibre optic output fibre optic cable 5m fibre optic receiver and lithium battery EEx proof Two sets each including an external solenoid valve which will be installed as close as possible to the fluid part but outside the high voltage area 8 2 Control components Item Name Part number 1 Touchscreen 2K 2052 2 Processor card 2K 2051 3 Motherboard 2K 3050 Page 54 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 8 3 Components of a typical low pressure fluid handling section 1 main col
44. nt this is first agitated for the set time Only then are the metering valves opened This always applies only to the agitators whose components are stored in the activated recipe Page 46 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 6 Maintenance 6 1 Cleaning and maintenance of the fluid handling section Protect the fluid handling section from spray mist If it is necessary to clean the area with thinners the power to the apparatus must be turned off because the metering sensors of the standard version are not EEx proof Generally the apparatus must be cleaned by a complete flushing procedure after the end of operations or during a prolonged spray interval to avoid hardening of the paint in the apparatus gt See 5 2 3 Start flushing procedure 6 1 1 Cleaning of hoses and tubes If the flushing procedures have been carried out properly a special cleaning of hoses and tubes is not necessary However if reactions occur inside the system replacement is advisable to avoid solid particles gradually coming off and entering the system 6 1 2 Maintenance of valves If a colour change valve has not been used for a prolonged period disassembly of the colour supply unit and flushing of the valve are recommended otherwise solid particles might settle inside the valve If the valves no longer operate properly or if air or fluid leaks occur the seals must be replaced Since the hardener valves are activated more frequ
45. of valves 1 8 Status outputs assigned as follows Mix OK System ready Flush Fill Drain valve System filled Alarm Pot life almost expired Constant connection 24V Switching side to GND of status functions Switching side to GND of valve functions Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 4 6 Pneumatic connections The apparatus in standard version will be supplied via a central air connection The pressure may not exceed 8 bar but must be at least 6 bar Please provide clean industrial air and ensure proper filtration and condensate separation Use oil free compressed air 4 7 Solenoid valve terminal The solenoid valve terminal comprises 8 x 3 way 2 position valves which can be used for different purposes but mainly to control the paint hardener and paint valves With the maximum complement of 32 valves 4 solenoid valve terminals are required The outputs are assigned as described on the following page Number Number Output at Valve Block valve terminal Sa 2 1 Sore a ae 4 1 4 el enn DE EE Weeer 2 2 Fig Solenoid valve terminal view from below 11 2 3 2 2 4 The lead colour coding for RES ea the solenoid valve terminal is follows 14 4 2 6 15 2 7 eet dE CECR 17 3 1 as DEEN oe BEE THE TE 2 Red er 43 4 3 Orange ed 4 Yellow 2 3 6 5 Green 23 3 7 6 Blue 24 3 a 7 Purple a as anal 8 Grey 6 4 2 27 4 3
46. our 1 hardener 2 cleaning agents Item Name Part number 1 Main colour valve CCV 403 SS 2 Cleaning agent valve CCV 403 SS 3 Cleaning agent valve 2K 4002 4 Hardener valve 2K 4002 5 Return valve 2K 2027 6 Mixing pipe 2K 2080 7 Pickup metering cell 2K 2016 Non EEx 2K 2017 A EEx 8 Gear wheel metering cell 2K 2015 Page 55 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 8 4 Assemblies with Spare Parts Lists 8 4 1 Fluid valve 2K 4002 high pressure i H 3 4 5 8 A A 28 8 21 9 il 27 6 5 3 8 2 N f 4 B x TS 2 e en B p ER de D if 16 12 A 14 13 E E Materialventl __ 2K 4002 1 2 3 4 Lfd Nr Serial no St ck Item Benennung und Fertigma e Name and finished dimensions Werkstoff Material Zeichnungsnummer Drawing number Bemerkung Comment nderung Change Datum Date Name Name Gezeichn Drawn Geh rt zur Zeichnung Belongs to drawing Gepr ft Checked Normeng Standard compliant Ma e ohne Toleranzangabe nach DIN ISO Dimensions without tolerance info
47. rrent flow rate is output in the range up to 1 0 l min 10V 1 0 litre min 0 5 0l min same function but 10V corresponds to a flow rate of 5 litre min 1st POT LIFE ALARM pot life pre alarm in minutes STOP AFTER FILLING indicates whether the apparatus closes the valves once again after filling ready to be released once more POT LIFE FACTOR safety factor for calculating the remaining pot life 200 means that double the filling quantity must be consumed to reset the pot life again to the initial value 150 means accordingly e g 1 5 times the filling quantity Page 43 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 5 5 13 Optional software only available for additional hardware options 5 5 13 1 Control of flushing pockets If the option for the control of up to four flushing pockets for handguns is connected to the system the following screen will appear after pressing the Spray key Guns 1 to 4 can be activated or deactivated individually on active off inactive The filling process will then be performed consecutively via the corresponding flushing pocket for each activated gun When changing paints or flushing the system only the guns that were active during the last spraying process will be cleaned one after the other The stored flushing process will then run exactly once for each gun This mask will only be called up if the spraying process is started via the display If
48. rvice manual If in doubt or if problems arise contact your superior or one of our distribution partners NEVER leave tools or other mechanical components in or on the apparatus if it is in operation or if it is about to be started up NEVER exceed the maximum pressure of the apparatus The maximum pressure of the apparatus is dictated by the component with the lowest maximum pressure You will find the maximum pressure of the apparatus on the type plate When replacing components ALWAYS ensure that the new parts comply with the technical data regarding fluid and maximum pressure ALWAYS ensure that the spray area is properly ventilated according to legal requirements The equipment must ONLY be operated by authorised and adequately trained personnel who have read and understood local codes relevant legal requirements and this service manual The personnel must wear suitable personal protection devices and clothing and use appropriate tools during operation and maintenance Before carrying out any maintenance work AWAYS ensure the pressure is relieved from all air and fluid hoses Shut off the compressed air supply to the apparatus and relieve all pumps connected to the apparatus Before carrying out any work in the electrical cabinet ALWAYS ensure the current supply is disconnected It is not sufficient that the main switch is in the OFF position You must cut off the power supply to the cabinet completely When working with high pre
49. solenoid valve no trigger air signal Check allocation of colour change valves to solenoid valves Colour change valve does not open although trigger air is applied Disassemble colour change valve clean replace seals see service manual for valve Lack of fluid Check fluid delivery system on B side empty container alternatively C side Defective feed pump Check functioning of pump see service manual of pump Blocked metering cell Start flushing procedure disassemble metering cell and clean if necessary Defective sensor on metering cell Contact service technician replace metering cell Cable rupture or wrongly connected Test cable replace if necessary Page 50 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 Fault Possible cause Remedy Alarm message As Mixing tolerance A B C exceeded only for components that are added Pressure differences too small added components do not enter mixture gt Recognisable through lack of injection noise Slowly increase hardener pressure increase needle stroke at metering valve Uneven operation of feed pumps Check pumps clean and replace packings if necessary Increment size selected too small Adjust increment size within the possibilities Flow rate too high for example by filling without spray tip Adjust increment size within the poss
50. ssure spray equipment ensure that the guns are NEVER operated without protection against accidental contact ALWAYS activate the safety locking lever when not using the gun in order to prevent unintentional opening of the guns When finishing maintenance and repair works replace properly ALL safety covers that have been removed from moving parts Only use original spare parts and accessories Failure to adhere to this renders any warranty claims invalid After a longer period of shutdown check ALL relevant components for leakage and proper function Page 7 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 2 3 Reaction hazard All fluid conducting parts of the apparatus are made of stainless steel in order to avoid possible chemical reactions However in individual cases a chemical reaction might occur if aggressive or chemically active media are being used which might lead in the worst case to disintegration or even to an explosion If you want to use such media contact the fluid manufacturer prior to operation in order to check the compatibility of the fluid with different kinds of stainless steel 2 4 Fire and explosion hazard caused by sparks High flow rates of non conductive materials can lead to electrostatic charging This phenomenon frequently appears with airless systems because the flow rate is very high and the fluid will be sheared and ruptured at a small gap In order to avoid charging and associated spar
51. t parameters it is necessary to be able to enter numbers Generally this is done using the input field shown below The value to be set is shown at the top left The value is deleted by pressing the DEL key one decimal place per key depression The value is entered into the system by pressing the numerical fields and by pressing the ENT field The name of the value here recipe i e recipe number is described below the value Page 15 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 5 2 Main menu 5 2 1 Select recipe a By pressing the recipe number here 1 you are asked to enter a new recipe number Possible inputs are all recipe numbers from 1 to 50 The name of the recipe is displayed below the recipe number On the icon Flushing the number of the stored flushing program 1 10 for this recipe will be displayed If you have chosen a recipe number that has been filed in recipe administration as inactive the display with the recipe parameters will flash You cannot start this recipe 5 2 2 Start spraying procedure kal Pressing the spray icon activates the mixing procedure provided that an active recipe was chosen beforehand 5 2 3 Start flushing procedure EI Pressing the flushing icon activates the flushing procedure The flushing procedure may be repeated as often as you wish for example if several spray guns are connected which are to be cleaned one after the other
52. uch the screen to return to the main menu Units of measurement pressing the appropriate button sets the system either to metric units ml I bar or to imperial units oz gl psi Recalculation is automatic Language settings Up to eight different language packages can be installed on the system The composition and positioning of the languages can vary Important a language must always be installed If no language package is specified please contact us After selecting the desired language please be patient the language first has to be loaded Page 32 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 Ann PUIU E GAUL Cer 5 5 5 Calibrate adjust K factors Te oe en Era ie is CHESS 22 23 2s 26 27 2s 29 s8 s1 zz 5 5 5 1 Manual adjustment of K factors For quick start up of the apparatus and for checking the functions generally it is normally sufficient to enter the K factors of the volumeter determined by the design into the system These are normally entered on delivery of the apparatus To take account of the different physical characteristics of the media to be metered a dedicated K factor can be entered for each valve and thus for each associated medium A high viscosity solvent based paint will produce a different K factor from a cleaning thinner or a water based paint at the same volumeter Press the individual number fields 1 32 to read the stored value If
53. value displays the capacity in litres for this container 2 Minimum level the programmed value indicates by which tank level the alarm will be activated 3 Level indicator the value displays the current fluid quantity in the tank No level control the tank has not been activated for tank monitoring Up to 8 tanks can be monitored with their own alarm output via the optional standard level output module By this means for example eight alarm lights can be activated individually in order to see immediately which tank has to be refilled Page 20 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 5 4 Flushing 4 lalye Dimension Oumpe 1 Current flushing step a flushing procedure may consist of up to 20 different steps All flushing steps for which values are stored are run in numerical order 2 Skip a flushing step if the current flushing step is to be skipped press the key and skip to the next flushing step for which values are stored 3 Valve number the flushing valve that is currently open is displayed 4 Flushing value stored set value of the flushing program optionally in ml or in sec see 4 5 Dimension displays whether the current flushing step will be carried out in millilitres or in seconds In principle cleaning of the apparatus in millilitres is a more reliable process However quantity recording is not sensible for steps which cause e g air solvent flushi
54. valve strokes since installation This can be helpful when servicing the valve Based on experience gained during operation of the system you can draw conclusions regarding the actual condition of the wearing parts on the valve ET STOP u EEE 1 Gun monitoring the number on the display indicates the time in seconds during which the gun has been open but no impulses were received from the metering cell As soon as the volume sensor measures a fluid flow the value drops back to 0 If the value increases up to the stored value for monitoring the gun the system will set off an alarm The gun is monitored via a sensor in the atomizer air For automatic guns the monitoring is carried out via a potential free contact which is closed by the higher level PLC 2 Volume flow the bar displays the output frequency of the volume sensor This is proportional to the measured volume flow 3 Valve status when the valve is activated ON will be displayed on the screen otherwise OFF The main component is permanently open Page 19 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 By means of this display hardware errors can be detected easily If for example the valve is ON but the value of the gun monitoring is increasing steadily then the reason will be that no fluid is flowing the metering cell is blocked or the flow sensor for the atomizer air is set incorrectly EEE 1 Tank size the
55. ware release 02 2011 6 Dump valve for each step in the flushing program it is possible to set whether the signal Dump valve is to be activated The signal can then be used to activate e g a gun cleaning box or whether the cleaning is to be carried out via an external dump valve drain valve 7 Loop start in the flushing program a loop can be programmed which carries out certain steps cyclically for a certain number of repeat options Here the first step of this loop will be displayed 8 Last step of the loop described under 7 9 Number of loop run throughs see 6 Ok 10 iw Key to store all modifications Page 27 of 74 Feb 2011 Magic Flow Rev 3 0 Software release 02 2011 ae 1 32 5 5 3 Valves Press the valve key to enter the manual control panel for the associated valves signal outputs optional and pressure regulator optional Keys 1 8 alternatively 1 16 or 1 32 depending on system configuration control the relevant valves For security reasons only one fluid valve can be opened at a time If you want to close all valves again press the key Valves OFF Keys S1 S8 control the special signals 1 Mixing OK S2 Ready S3 Flushing S4 Filling S5 Dump valve S6 Filled S7 Alarm S8 Alarm prior to expiry of pot life Press the key Signals OFF to turn off all outputs Keys F1 F4 control gun extractor units 1 to 4 Keys D1 D4 control colour distributor
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