Service Manual "Magic Flow"
Contents
1. 5 1 2 L 8 11 12 No Qty Name and finished dimensions DIN Material Remarks 1 1 End plate push fit fitting 14305 2K 4121 2 1 Spacer 14305 2K 4122 3 1 End plate G 1 4i 14305 2K 4123 4 O ring 10 x 2 Viton B E 2K 4124 D Hex socket screw M4 x 40 981 8 8 vz 2K 4125 6 _ Dummy plug E pM 14305 2K 4126 7 Plug G 1 4i B 4114305 2K 4127 8 4 Clamping screw M5 x 16 IP1 31 912 8 8 vz 2K 4128 9 4 Clamping screw M5 x 60 IP1 912 8 8 z 2K 4129 1x2431 10 4 Clamping screw M5 x 100 IP1 912 8 8 vz 2K 4130 2x2 31 11 4 Clamping screw M5 x 140 IP1 912 8 8 vz 2K 4131 3x2431 12 4 Spring washer A5 7980 2K 4132 13 O ring 10 x 2 Viton 2K 4133 Page 55 of 66 Feb 13 2K 2027 Return valve 14 BSP gt M16x1 5 2K 2029 Color change stack 2 2 until 2007 2K 2030 Color change stack 4 2 2K 2031 Color change stack 6 2 until 2007 2K 2032 Fitting 4 BSP gt M16x1 5 Page 56 of 66 Feb 13 2K 2033 Screw plug 4 BSP short version for color change stack 2K 2034 Disc washer Stainless Steel for color change stack until 2007 2K 2035 Adapter for high pressure valve on color change stack until 2007 2K 2036 Seal 4 aluminum Page 57 of 66 Feb 13 51410L 14 Adapter adjus2. Page 48 of 66 Feb 13 Pos Oty Unit Name Standard code Remarks designation 1 l pcs Valve body 2K 4100 2 l pcs Air cylinder 2K 4101 35 l pcs Cap 2K 4102 4 l pes Piston 2K 4103 5 pes Nut 2K 4104 6 2 pcs Spacer 2K 4105 7 1 pes Packing holder 2K 4106 8 4 pcs Fillister head screw M4 x 40 DIN 912 8 8 vz 2K 4107 9 l pcs Sealing ring 12x 16x 1 5 2K 4108 10 2 pcs Sealing ring I4 x 18 x 1 5 2K 4109 I l pes Fastening screw G ba 2K 4110 12 l pes Compression spring 2K 4111 13 l pcs Compression spring 2K 4112 14 l pes O ring 25 3 x 2 4 2K 4113 15 l pcs O ring 3 3 x 2 4 2K 4114 16 17 l pcs Seal kit 3x diaphragm 3 x O ring 2K 4115 1858 pes Valve needle 2K 4116 gt pcs Locking piece with valve seat 11 16 x 16 UN 2K 4117 24 l pcs Screw plug GY 2K 4118 28 l pcs O ring 10 x 2 Viton 2K 4119 29 4 pes Spring washer 4A DIN 7980 vz 2K 4120 Page 49 of 66 Feb 13 8 2 3 Material Valve CCV 403 SS E Low Pressure 13 12 10 1 z 14 isa 7 2 4 35 Fi x FC HERE BEE BE e Fa F vase IY i SS Eth Nie 1 Z III SA AID _ 4s u 16 17 14 19 B Benennung eile Nr eichn Nr Bemerkungen Description Part No Draw No Remarks Supplier zZ Steuerlufteingang 1 8 NPT F roti Air Inlet 1 8 NPT F C C
3. 9 9 8 9 9 9 9 9 10 9 9 11 9 9 12 9 9 13 5 5 14 9 9 15 Reports V O C Values Alarm Memory Security Codes Time PLC Update Display Update Optional Software 5 5 15 1Control Flushing Pockets 6 Maintenance 6 1 6 1 1 6 1 2 6 1 3 6 2 Cleaning and Maintenance of Material Component Cleaning of Hoses and Tubes Maintenance of Valves Maintenance of Metering Cells Cleaning of Control Module 7 Troubleshooting and Alarm Messages 8 Spare Parts and Options 8 1 8 2 8 2 1 8 2 2 8 2 3 8 2 4 8 2 5 8 2 6 8 2 Spare Parts and General Options Components with Spare Parts Lists Material Valve 2K 2014 Material Valve 2K 4002 Material Valve CCV 403 SS E Low Pressure Volumeter Air Flow Monitor Accessories Material Valve Touch Panel 9 Installation Shut Off 10 Annex 10 1 10 2 10 3 Flow Chart Connect Material Component and Electrical Cabinet Technical Characteristics Personal Notes Page 3 of 66 Page 33 Page 34 Page 35 Page 36 Page 37 Page 38 Page 38 Page 39 Page 39 Page 40 Page 40 Page 40 Page 40 Page 40 Page 41 Page 44 Page 44 Page 47 Page 47 Page 48 Page 50 Page 52 Page 54 Page 55 Page 59 Page 60 Page 61 Page 62 Page 64 Page 65 Feb 13 EG Konformit tserkl rung im Sinne der EG Richtlinien Maschinen 93 68 EWG Anhang II B Elektromagnetische Vertr glichkeit 89 336 EWG ge ndert durch 92 31 EWG Niederspannung 73 23 EWG Die Anlage Ma
4. Reset key on the PLC main board 5 5 14 Display Update Software Update The display too should receive new updates in exceptional cases only and only by authorized and qualified personnel However should you press this key PLC switches into the receive mode for new display software which in turn will be transferred to the display by PLC The display signals Waiting for data You can only return from this mode to the normal operating mode by turning off the power supply or by pressing the Reset key on the PLC main board Page 38 of 66 Feb 13 5 5 15 Optional Software Only Available for Additional Hardware Options 5 5 15 1 Control 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 The guns 1 to 4 can be activated or deactivated individually on active off inactive The filling process will then be performed one after the other for 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 defined flushing process will then run exactly once for each gun This mask will only be called up if the flushing process is started via the display If the mixing process is called up via a remote control or a robot communi
5. 13 12 igtbuee DOS 2 A 13 yellowmhite DO4 2 A 14 X ydow DOS 2 A 15 redgreen DO6 2 A 16 orange DO7 2 A 17 orangemhite DOO 3 A 18 gen DO 3 A 19 yelowbdak DO2 3 A 20 white DOS 3 A 21 X whitbuee DO4 3 A 22 bow DO5 3 A 23 greenwhie DO6 3 A 24 rd DO7 3 A 25 bluebak DOO 4 B 26 redberom DOI 4 B 27 whit lllack DO2 4 B 28 redbue DOS 4 B 29 blakoang DO4 4 B 30 yelowed DO5 4 B 891 blackbow n DO6 4 B 32 white red DO 7 4 B Page 63 of 66 Feb 13 10 3 Technical Characteristics General Data Kind of protection of the control part IP 52 Kind of protection of the fluid part EEx proof for operation in EEx Class 2 Optional EEx proof for operation in EEx Class 1 Materials for fluid contacting parts Stainless Steel PTFE Polyamide Special Data Software Freely adjustable recipes 50 Trigger able components 32 Deposit able parameters No A B C mixture ratio Pot life optional fluid pressure Adjustable flushing parameters 20 steps valve number each quantity or time dump valve Storage of consumption of all components Mixture ratio 0 200 metering on to main component 100 Hardware Mi
6. mono diaphragm pumps or by pressure tanks Care must be taken that all components are operating in a similar pressure range The combined operation with pressure tanks and high ratio piston pumps is not recommendable It must be ensured that that the components of side B eventually also side C have a higher pressure approximately 1096 than side A in order to be metered and added on For proper operation of the installation at least the following equipment is necessary One fluid supply for side A One hardener supply for side B One flushing agent supply according to paint system two off are possible f necessary one thinner supply for 3C installation Page 9 of 66 Feb 13 A Installation 4 1 Transportation The installation consists depending on the design of one or two modules which can be transported separate from each other The transportation will be done on pallets For the handling two persons are needed 4 2 Storage If the installation shall be stored the control part must be protected against heat and humidity In order to avoid condensation of water the installation must not be exposed to high temperature changes otherwise the installation must be exposed to the new ambient temperature with flaps open for several hours prior to operation The material component is extensively resistant against external influence however for a longer period of storage it should be filled with preservative
7. 13 5 5 6 Container Control EREuEZ Sn E 2888ml The integrated container control serves the control of the container level without additional sensory mechanism If a container shall be controlled it is necessary to deposit into the menu its level prior to use otarting from the metered consumed material quantity the system can give an alarm signal if a defined minimum level is reached in order to avoid no load operation of the pumps with the result of defective mixtures and failures With the buttons 1 32 the container will be selected which shall be adjusted or controlled With the button MAX LEVEL the size of the container will be determined which it had when delivered ACTUAL CONTENT displays the actual 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 given if the level falls under this value Press the button to adjust the level ACTIVE resp NOT ACTIVE will display whether the control shall be activated If the button is in ACTIVE mode an alarm signal will be given If the button is in NOT ACTIVE mode the container level will be calculated but the minimum level will be ignored Page 31 of 66 Feb 13 5 5 7 Printer Configuration MagicFlow PRINTING AFTER ml 1 OO J PRINTING K AFTER sec UNIT ID displays the name of the mixing installation which app
8. Lack of material Check material supply 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 Meter cable replace if necessary Page 42 of 66 Feb 13 General Problem Possible Cause Solution Alarm Message Mixing tolerance A B C exceeded Difference of pressure too high injections too large gt Recognizable by heavy pulsations atthe gun Slowly reduce hardener pressure reduce needle stroke at metering valve Uneven operation of feed pumps Check pumps clean and necessary replace packings if Incremental size selected too small within the possibilities Adapt incremental size Flow rate too high for example by filling without Spray tip Only fill with tip Adapt incremental size within the possibilities General Problem Possible Cause Solution Alarm Message Potlife expired Installation has not been flushed in good time Start flushing procedure Not sufficient material removed from installation within pot life pe
9. a central air connection The pressure must be at least 6 bar and must not exceed 8 bar Please provide clean industrial air and proper filtration and condensate separator Use oil free pressure air 4 6 Material Connections The material component must be supplied with at least depending on the number of components one main color one hardener and one flushing agent The outlet of the static mixer must be connected to the gun the guns with a suitable fluid hose please refer to length and nominal pressure The hoses must be equipped with adequate hose connections according to the installation The threads must be in proper condition and must seal under pressurized condition Page 11 of 66 Feb 13 5 Operation of the Installation 5 1 General 5 1 1 Turn on the Installation Turn on the installation by turning the main switch into position ON Only turn the installation on if the control cabinet is closed high voltage Opening of the control cabinet at ON condition must only be done by qualified personnel and a service technician Generally it is not necessary to turn off the installation If the installation is in the main menu and has been cleaned the screen will independently turn off after an adjustable period of time see system settings value Standby Do not turn off the installation in filled condition control of the pot life will than no longer be possible resulting in the danger of material hardening in the
10. installation 5 1 2 Input of Numbers To set the different parameters it is necessary to be able to enter numbers Generally this will be done by the input field shown below The value to be set is shown at the upper part on the left side The value will be deleted by pressing the DEL key one decimal place each per key depression The value will be entered into the system by pressing the number fields and by pressing the field ENT The name of the value here recipe i e recipe number is described below the value Page 12 of 66 Feb 13 5 2 Main Menu 5 2 1 Select Recipe Rezeptname 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 Below the recipe number the name of the recipe will be displayed 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 which has been deposited in the recipe administration as an inactive one the display with the recipe parameters will flash You cannot start this recipe 5 2 2 Start Spraying Procedure gt Press the spray icon The icon activates the mixing procedure provided that an active recipe was chosen before 5 2 3 Start Flushing Procedure CE Press the flushing icon The icon will activate the flushing procedure The flushing procedure may be repeated as often as you wis
11. press the above shown key icon 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 Finishing Brands Binks After input of the code you press the field the menu of which you want to secure with a new password You will see the input picture new code Enter here your new secret number The code will automatically be stored If you should forget or mislay your access code you can also use this procedure in order to find out the deposited code But carefully keep the master code because it is an unchangeable part of the software of the control Page 36 of 66 Feb 13 SET CLOCK 5 5 12 Time Press the key SET CLOCK in order to set the internal clock of the installation The clock has a movement reserve of approximately 10 14 days The clock is necessary to print reports and for storing alarm messages To change values you press the keys To store the modifications you press the key OK Page 37 of 66 Feb 13 PLU UPDATE 5 5 13 PLC Update Software Update The PLC should receive new updates in exceptional cases only and only by authorized and qualified personnel However should you press this key the installation switches into the so called HOST Mode in which it is ready to receive new software You can only return from this mode to the normal operating mode by turning off the power supply or by pressing the
12. 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 deposited in the system settings In order to guarantee highest possible safety the function of the metering sensors will be controlled on the one hand and on the other hand the installation will be shutdown if the demanded mixture ratio has not been achieved e g insufficient material On the basis of the high precision of the mixing and the controlled and economic treatment with solvents and paint materials the electronic mixing and metering installations are clearly superior to the mechanical metering installations 3 2 Mixing The installation is designed to regulate and inject the B component optional 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 installation not included in scope of delivery of basic installation 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 depending on the used paint material 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 Material Supply Material supply will be made either by piston pumps double diaphragm pumps and
13. retrofit to another volumeter you can do this by pressing the number input icon C 5 5 5 2 K Determine K Factors To increase the accuracy of the mixing installation it is recommendable to calibrate all fluids Follow the steps hereafter a 1 Press the icon with the mixing cup Page 28 of 66 Feb 13 2 Select the volumeter that shall be calibrated 3 Select the valve with which shall be calibrated Page 29 of 66 Feb 13 4 Carry out the metering The bar on the left side indicates the flow rate If the bar does not deflect upwards when removing material you have either selected a valve which is not allocated to the selected volumeter or the metering cell is mechanically blocked The number on top right indicates the count of impulses Open the spray gun at first and remove material The count up counter must now display an increasing value With the START RESET key you can reset the count up counter to Zero Press the key after having filled the system with material wait for some seconds and start the actual metering Remove a well readable quantity of material into a metering cup Close the spray gun and wait for some seconds until the count up counter has come to standstill Finally press the OK key You will then be asked to enter the volume of the removed material The resulting K factor will be displayed and will then be entered into the system Page 30 of 66 Feb
14. 5 9 Press the key PRINT ALL in order to print the consumption value of all components as far as the optionally available printer is connected Page 33 of 66 Feb 13 5 5 9 V O C Values LI Ll m Press the keys 1 to 32 to select the valve respectively the component where you wish to adjust the VOC value The VOC value in will be displayed in the mid Press the key V O C to adjust the value for each valve separately The value is needed in order to calculate for the consumption reports not only the consumption but also the VOC emission Page 34 of 66 Feb 13 ALARM EVEN TS 9 9 10 Alarm Memory The mixing installation stores up to 100 alarm messages in sequence of appearance You can scroll through the alarm history with the keys and gt If more than 100 errors were collected the last 100 messages are still available Each alarm message is listed with date and time as well as with the reason for the alarm The significance of the alarm icons you will find in the Chapter Alarm Messages Page 35 of 66 Feb 13 et CODES 5 5 11 Security Codes When delivered all menus are accessible without code input Input O After installation and initial operation all security relating settings should be secured against unauthorized access The setting of the passwords will be done in the same manner as an eventually later necessary adjustment of the codes To set acode you
15. Service Manual Magic Flow MAGIC ZLOW ye BINKS Page 1 of 66 Content Identification Data 1 1 1 Preface 1 2 Identification of the Installation 1 3 Limited 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 6 Injection Hazard 2 7 Hazard by Escaping Liquids 2 8 Emergency Shutdown 2 9 Residual Pressure 3 Description of the System 3 1 3 2 3 3 Functional Characteristics Mixing Material Supply 4 Installation Transportation Storage Installation Electrical Connections Pneumatic Connections Material Connections 5 Operation of the Installation 9 1 9 1 1 9 1 2 9 2 9 2 1 9 2 2 9 2 3 General Turn on the Installation Input of Numbers Main Menu Select Recipe Start Spraying Procedure Start Flushing Procedure Adjust Settings Painting Mixing Flushing Settings Recipes Administration of Flushing Valves system Settings Calibrate Adjust K Factors Manual Adjustment of K Factors Determine K Factors Container Control Printer Configuration Page 2 of 66 Page 5 Page 5 Page 5 Page 6 Page 6 Page 7 Page 7 Page 7 Page 7 Page 8 Page 8 Page 9 Page 9 Page 9 Page 10 Page 10 Page 10 Page 11 Page 11 Page 11 Page 12 Page 12 Page 12 Page 13 Page 13 Page 13 Page 13 Page 14 Page 15 Page 18 Page 20 Page 21 Page 23 Page 25 Page 26 Page 28 Page 28 Page 28 Page 31 Page 32 Feb 13
16. ad to dissolution or in the worst case to an explosion If you want to use such materials 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 High flow rates of non conductive materials may lead to an electrostatic charging This phenomenon frequently appears with airless systems because the flow rate is very high and the material will be sheared and burst off at a small gap In order to avoid charging and spark discharge all components must be electrically connected with each other and grounded Use suitable clamps and clean the contact parts of Spray mist if necessary Connect the clamps via suitable cable with sufficient mass potential permanently installed tubes etc If an electrostatic charging occurs check for proper grounding 2 5 Toxic Solvents Toxic and harmful vapors may be set free by the spray and mist of paints and other materials Follow all safety instructions of the manufacturer 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 The spray stream of high pressure spray equipment can puncture the skin and cause great harm If such an incident occurs in spite of all s
17. afety precautions seek medical care immediately and inform the doctor about the penetrated material see material data sheet 2 7 Hazard by Escaping Liquids Never modify the connections of the installation without prior contact with a responsible person Regularly check the condition of hoses and connections Take care that hoses are not crushed and bent below the allowed radius Never overstrain hoses and connections by high mechanical load Immediately replace damaged hoses Page 7 of 66 Feb 13 Check all connections prior to operation Never try to stop or deflect leaking material 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 in OFF position This will set all components of the panel current less 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 depressurized as pressure can only be relived into one direction In order to depressurize the complete installation open the spray gun und the relevant valves via the control device if no relief device is installed at the pumps Page 8 of 66 Feb 13 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
18. b 13 8 2 4 Volumeter 2K 2015 Bole X Dum TB SB Sa i S3 ape m m S2 8 2 lis g A No gt i 9 2 a Oa a IQ S 3 x N L A IA ul nes ze ssejsny A sseui A PELLIS MEAN 149 JOsuasuauin oA qu 4DBtH8ugnpjaezur3 piuagniuasuy X YSU eZ aqneuy gt ssbunbiysajag Page 52 of 66 Feb 13 Spare Parts for Volumeter 2K 2015 For the volumeter the following spare parts and wear parts are available Pair of gear wheels 2K 2019 Shaft gear wheel 2K 2020 Disc washer material PTFE 2K 2057 or Disc washer material Viton FEP sheathed 2K 2058 Other volumeters are available on request higher or lower resolutions various bearings Page 53 of 66 Feb 13 8 2 5 Airflow Control for Atomizing Air LG 518 GSP Part No 2K 2053 DC 24V PNP Ausgang Analog Ausgang LED Anzeige Lufterfassungsbereich 0 5 15 m s Abmessungen g 3 A e S 2a e 27 Pot Pot Pot LED LED LED Ausgang m I Ee I PNP 4 20 mA PNP 4 20 mA Typ LG 522 GSP Schaltstrom im 20 20 20 Ve a aa Ea Umgebungstemperatur PC 2220 20 PBT Ms Ni PNP Betriebsspannung Bereitschaftszeit Geh usewerkstoff Schutzart EN 60529 Page 54 of 66 Feb 13 8 2 6 Accessories Material Valve New paint changing system from the 4 quarter of 2007 High pressure valve 2K 2004
19. card white lead onto CNT of the CNTO insert card connect also CNT with GND via a cable jumper on the CNTO insert card Hardener black and brown lead onto 24V of the CNT1 insert card blue and silver lead sheath onto GND of the CNT1 insert card white lead onto CNT of the CNT1 insert card connect also CNT with GND via a cable jumper on the CNT1 insert card 3 Connect the control cable of the solenoid valve island as follows The solenoid valve island has a 25 channel cable orange The green back lead builds the 24VDC reference connection all other cables will be connected to the digital output cards of Magic Flow The output cards have 10 connecting terminals GND 24V DO O DO 1 DO2 DO 3 DOA DO 5 DO 6 DO 7 Attention GND will not be wired Via an address jumper it can be defined which solenoid valves will be triggered by the respective card Valves 9 16 Valves 17 24 Valves 25 Card 2 Card 3 Card 4 A solenoid valve island can have a maximum of 24 off 3 2 control valves If more than 24 valves shall be triggered another solenoid valve island is necessary In the following chart the first solenoid valve island is called A and the second solenoid valve island B If using a second solenoid valve island the green black lead must be connected to 24 V of card 4 Green black of the first solenoid valve island must be connected to 24 V of card 1 Page 62 of 66 Feb
20. cation module the last selected gun combination will be automatically applied again Page 39 of 66 Feb 13 6 Maintenance 6 1 Cleaning and Maintenance of the Material Component Protect the material component from spray mist If it is necessary to clean the area with thinner the power of the installation must be turned off because the metering sensors of the standard version are not EEx proof Generally the installation must be cleaned by a complete flushing procedure after end of operation or during a longer spray interval to avoid hardening of the paint material in the installation 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 recommendable in order to avoid solid parts coming off and entering into the system gradually 6 1 2 Maintenance of Valves If a color change valve has not been used for a longer period it is recommendable to disassemble the color supply unit and to flush the valve otherwise solid parts might settle inside the valve If the valves do not operate properly or if air or fluid leaks occur the seals must be replaced Since the hardener valves are activated more frequently a regular control of the valves is absolutely necessary It is recommendable to service the valves in regular intervals You will find furth
21. dentification of the Installation If you do have any questions regarding the product please note the exact type identification of the installation You will find it on the type plate of the installation This will help to identify the installation regarding modification and equipment so that we can offer qualified help to you 1 3 Limited Warranty All Finishing Brands equipment and spare parts are manufactured of the best materials and with the most modern production procedure Should you still have reason for a claim send the defective part or the defective component directly to Finishing Brands or to our distributor Please understand that we cannot accept any unfranked delivery If your warranty claim is legitimate we will refund transportation costs to you We will check replace or repair defective parts that fall within the warranty The repair will be made in our house If you wish the repair to be carried out at your site you will be charged for any eventually arising travel costs If in our opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained we will assume no responsibility for repair or replacement of the item or items Excluded from the warranty are normal wear parts i e gaskets packings and nozzles Page 5 of 66 Feb 13 Warranty period will be twelve months at one shift operation respectively six months at two shift and three shift operation sta
22. e entered as 100 25 During the mixing procedure the main component will automatically be determined by the greatest portion of the total mixture and permanently opened while the other components will be metered on Only enter values under C if the installation is equipped as 3C installation Ensure that the entered valve numbers are really connected to the relevant metering cells Adjust the pot life of the relevant mixture under t min in minutes Page 21 of 66 Feb 13 If an automatic pressure adjustment kit optional is connected to the installation 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 close them off 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 loads down again all 50 recipes from the system memory The icon with the disk stores all modifications and will lead you back to the tool menu ATTENTION During the cancelling or saving process the control unit requires a few seconds either in order to write the data of 50 recipes to the EEprom or to read them on the EEprom For thi
23. ears on the prints It is therefore possible to distinguish between the prints of different installations The name can have up to 10 characters PRINTING AFTER ml displays in which intervals process information shall be printed In the above shown case a print would be started after every removal of one liter material PRINTING AFTER sec displays the intervals during the mixing procedure when prints shall be printed It is possible to activate the two print variants but also only one or none of them If you do not wish to have prints made set the values to 0 Set the following parameters on the printer interface that is provided as standard serial Baud 9600 8 bit no parity 1 stop bit no hardware handshake Page 32 of 66 Feb 13 5 5 8 Reports PRINT ALL Use the keys 1 to 32 to select the valve respectively the component 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 therefore possible to collect the weekly consumption for example The operator can reset this value with the key RESET JOB As well as at the count of total consumption as at the job count the consumption of the component is listed and its VOC content The relative VOC content in percent can be set in the VOC Menu see 5
24. er directly signal lights horns etc 2K 2049 Switching power supply 230VAC 24VDC3 2A 75W top hat mounted 2K 2073 Line safety switch Characteristics B16 2K 2050 Main board supplied without output cards supplied without display 2K 2051 Processor for main board Chip set Siemens Infineon Cl144 pre programmed 2K 2052 Touch screen LCD display with analogue touch field 240 x 128 Pixel CFL lightning blue white pre programmed for Magic Flow 2K 2074 Optoelectronic coupler input card Optoelectronic coupler input 24VDC signal connection for power supply signal transmitter 2K 2064 Air flow control adjustable air connections 3 8 F 24V power supply signal output 24V PNP switching Page 44 of 66 Feb 13 Merchandise Group Spare Parts Magic Flow 2K 2011 2K 2012 2K 2071 2K 2070 Solenoid valve plate 3 2 controls Magic Flow 2 x 3 2 controls 4mm Solenoid valve plate 5 2 controls Magic Flow 1 x 5 2 controls 4mm Integrated gauge Magic Flow 010 bar 40 mm front montage Air regulator Magic Flow 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 2022 Volumeter Magic Flow Volumeter Stainless Steel 1 4 F P max 250 bar metering range 50 2000ml min slide bearing Single Pickup Magic Flow Pickup for volumeter not EEx proof connection M12 four conductor Single Picku
25. er details in Annex 10 5 6 1 3 Maintenance of Metering Cells Generally our metering cells are maintenance free If it should be necessary to clean blocked metering cells please note Metering cells have to be treated according to the instructions of the manufacturer Annex 10 4 The accuracy of the metering cells must be controlled in regular intervals calibration because the use of abrasive or pigmented fluids will lead to wear which influences the accuracy of the gear wheels 6 2 Cleaning of Control Module The control module must only be cleaned with a soft cleaning agent There are no internal components or assembly groups which need cleaning or maintenance Page 40 of 66 Feb 13 Cleaning of the touch screen display with solvents is not allowed If you expect high grade contamination of the display there are slightly self sticking transparent protection foils available which can easily be exchanged 7 Alarm Messages and Troubleshooting General Problem Possible Cause Solution Alarm Message no volume flow A side Atomizing air is open without spraying Set longer activating time for metering cell control Do not open atomizing air unnecessarily Tip clogged no material flow with gun open Clean tip replace if necessary Color change valve connected to wrong solenoid valve no trigger air signal Check allocation of color change valves to solenoid valv
26. es Color change valve does not open although trigger air is applied Disassemble color manual for valve change valve clean replace seals see service Lack of material container Check material supply system on A side empty Defective feed pump manual of pump Check functioning of pump see service Blocked metering cell and clean if necessary Start flushing procedure disassemble metering cell Defective sensor on metering cell metering cell Contact service technician replace Cable rupture or wrongly connected necessary Meter cable replace if Page 41 of 66 Feb 13 General Problem Possible Cause Solution Alarm Messaae no volume flo side Atomizing air is open without spraying Set longer activating time for metering cell control Do not open atomizing air unnecessarily Hardener pressure too low Set hardener pressure to pressure of main color approximately 10 Tip clogged no material flow with gun open Clean tip replace if necessary Color change valve connected to wrong solenoid valve no trigger air signal Check allocation of color change valves to solenoid valves Color change valve does not open although trigger air is applied Disassemble color change valve clean replace seals see service manual for valve
27. ession 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 into each valve some miilliliters preservative agent and close it with a screw plug Remove the electrical and pneumatic supply connections Store the installation at a dry location Page 60 of 66 Feb 13 10 Annex 10 1 Flow Chart usjusuoduoy g T2423Tussg7 pm p i d u UU li pU i j pamm j e Pa ri aant y amm F m i p z i i po i UsjJusuoduoy u L t Pm nd Zu pu 1 1 u Legend Fluid supply system e g piston pump Spray applicator e g manual gun Filter Return valves spring tensioned Flow metering cells Static mixer Control cabinet Solenoid valve Color change valve v7 N CO TL OR OO Feb 13 Page 61 of 66 10 2 Connect Material Component and Electrical Cabinet The material cabinet and control cabinet are delivered separately in the basic version After mechanic assembly air and cable connections must be made between the two separate units Proceed as follows 1 Connect the air outlet of the electrical control cabinet with the air inlet of the fluid cabinet 10 mm air hose 2 Connect the metering cell cables yellow as follows Main color black and brown lead onto 24V of the CNTO insert card blue and silver lead sheath onto GND of the CNTO insert
28. h for example if several spray guns are connected which shall be cleaned one after the other If the icon flashes the Page 13 of 66 Feb 13 installation has not yet been cleaned after the last mixing procedure and the remaining pot life will still be counted down The pot life will only be reset to the start value after a COMPLETELY PERFORMED flushing procedure The flushing program that was activated during the last mixing procedure will be selected by default Therefore it is not important which flushing program number is displayed on the icon but which recipe was started and stopped last PAS 5 2 4 Adjust Settings S This icon will lead you to the system settings Here you can change for example recipes operating parameters and safety settings According to the setting the different sections may eventually only be entered via passwords Page 14 of 66 Feb 13 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 pot life 81 53 44 STOP P u hu JE 1 On top of the screen on all displays the set value of the mixture ratio and the selected valves will be displayed 2 Below you can read the actual values The measured value for each component is displayed in milliliters and in percent 3 At this position you can read the total consumption This is importa
29. have read and understood local codes appropriate legal requirements and this service manual The personnel must wear personal protection clothes and use appropriate tools during operation and maintenance Before attempting any work AWAYS ensure the pressure is relieved from all air and fluid hoses Shut off pressure air supply to the installation and relieve all pumps connected to the installation Before attempting any work at the electrical cabinet ALWAYS ensure the board is current less It is not sufficient that the main switch is in OFF position You must interrupt the complete current supply to the board When working with high pressure 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 from unintended opening When finishing maintenance and repair works replace ALL protection covers that have been removed from movable parts Page 6 of 66 Feb 13 The use of other than genuine spare and accessory parts will void warranties After a longer period of shutdown check ALL components for leakage and proper function 2 3 Reaction Hazard All fluid conducting parts of the installation are made of stainless steel in order to avoid possible chemical reaction However in individual cases a chemical reaction might occur if aggressive or chemically active materials are being used which might le
30. ing the gun sometimes to blow dust from the object Display Brightness Enter the value for the relative display brightness in percent 0 100 Attention 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 Standby Time The standby time in seconds indicates after which time period the display turns off for longer service life of the lightning cathode The installation only switches to standby mode if it is flushed and if it is in the main menu all valves closed If the installation is in standby mode it is sufficient to touch the screen to return into the main menu Page 27 of 66 Feb 13 AJUU x B JULM B HU Coote 5 5 5 Calibrate Adjust K Factors KENZEZEE 5 5 5 1 K Manual Adjustment of K Factors For quick operation of the installation and for the general control of functions it is generally sufficient to enter into the system the construction wise given K factors of the volumeter They are generally entered when the installation is supplied To take account of the different physical characteristics of the fluid to be metered an own K factor can be entered for each valve and for each connected fluid At the same volumeter a highly viscose solvent based paint will cause another K factor than a cleaning thinner or a water based paint Press the single number fields 1 32 to read the deposited value If you wish to change this value e g after
31. ions 2 strokes total the total number of strokes since the installation This can be helpful for the servicing of the valve Based on experience gained during the operation of the system you can draw conclusions on the actual condition of the wearing parts on the valve EEE 1 Monitoring of the gun The number on the display indicates the time in seconds during which the gun has been open however did not receive any impulses of the metering cell As soon as the volume sensor is measuring a material flow the value drops back to 0 If the value increases up to the stored value for the monitoring of the gun the system will set off an alarm The monitoring of the gun is performed via a sensor in the atomizer air For automatic guns the monitoring is performed via a potential free contact which is closed by the higher level SPS 2 Volume flow The bar displays the output frequency of the volume sensor It is proportionally 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 16 of 66 Feb 13 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 cause will be that no material is flowing or the metering cell is blocked or the flow sensor for the atomizer air is se
32. le stroke of the metering valve flow rate viscosity and many others Generally the incremental size should be adjusted in such a way that mixing of the material in the mixer can just be carried out An incremental size of 100 ml for a static mixer with filling volume of 20 ml may have the result that the material will not be mixed accurately but that the installation still operates without error signal Metering Cell Control The indicated value indicates how long the Spray gun may be opened without the metering cell having to move The control 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 directly be given by an external control When the painter opens the gun the material flow should start shortly afterwards and activate the gear wheels of the metering sensors As long as a movement will be recognized and impulses of the metering cells to the control of the mixing installation are given the control of the metering cells will be reset If however a metering cell is blocked because of contamination so that it cannot recognize a volume flow the installation will give an alarm signal after the here deposited time The time should be in the range of 5 10 seconds in order to guarantee that no unmixed material can escape the gun However the time should not be chosen too short less than 3 seconds since the painter is us
33. nstallation in milliliters is process safer However a quantity collection is not sensible for steps which cause an air solvent flushing Therefore the dimension can be determined for each flushing step separately see flushing programming 6 Dump valve It is possible to deposit for each step in the flushing program whether the signal Dump Valve shall be activated This signal can then be used to activate a gun cleaning box or whether the cleaning shall be carried out via an external dump valve 7 Begin loop If a loop was programmed in the flushing program which in wraparound manner carries out certain steps for a certain number of repeat options then the first flushing step of this loop can be displayed here Page 18 of 66 Feb 13 8 Last step of the loop described under 7 9 Number of loop running see 7 OK 10 Ww This key will truncate the flushing procedure and will close all valves WARNING If the flushing procedure will be truncated the installation is still regarded to be filled The pot life is therefore still running 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 recognizes this module during the switch on the operator will be prompted during the start up of the spraying process to enter the spray guns that should be activated When the system will be flushed at a later stage the en
34. nt for e g the filling quantity of the system or the resetting of the pot life 4 Remaining pot life The basic pot life will be stored in the recipe If not enough material 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 a complete exchange of the material Example If the filling quantity is determined at 200 ml and stored on the system system settings the pot life will be reset to the initial value after the removal of 400 ml respectively 5 Using the arrow key will take you to the previous display 6 By pressing the Stop key the mixing procedure will be stopped 7 Using the arrow key will take you to the next display Page 15 of 66 Feb 13 Strokes nou strokes total F t lLife 81 586 54 1 strokes now the total number of strokes of the material valves in this recipe since the start of the mixing procedure The main component stays at 0 because the valve will only be 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 inject
35. oil in order to take care of the packings and to guarantee proper operation Operate the supply pumps according to the relevant service manuals of the pumps 4 3 Installation Generally the industrial installations of Finishing Brands will be installed by own service technicians or service technicians of our representative This is to avoid faults at the very beginning caused by defective installation or operation If installation shall not be made by an Finishing Brands service technician check the completeness and the correct function of all components of the scope of delivery For installation always take care of the usability of the installation the ambient conditions e g EEx explosion proof and the safety of the operator WARNING the control cabinet cannot be located in the EEx area If operation in the EEx area is necessary a remote control panel is optionally available Page 10 of 66 Feb 13 4 4 Electrical Connections The installation will be supplied via a central electrical input at the control cabinet Pay attention to proper grounding of the necessary shock proof plug In the basic version the fluid cabinet material component and the electrical cabinet will be delivered separately The connection of the two parts will be carried out according to the description under Pos 10 2 Connect Material Component and Electrical Cabinet 4 5 Pneumatic Connections The installation in standard version will be supplied via
36. ons Start Stop Flushing 3 off P E converter and 3 off pneumatic buttons 2K 2072 Isolated design 2 off metering cells Magic Flow Dual pick up for metering cell with fiber optic output fiber optic cable 5m fiber 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 Page 46 of 66 Feb 13 8 2 Components with Spare Parts Lists 8 2 1 Service Kits Material Valve 2K 2014 Service Kit 2K 2044 includes the items 6 9 and 14 1 each Service Kit 2K 2059 includes the items 2 3 7 10 11 14 15 and 20 1 each Page 47 of 66 Feb 13 8 2 2 Material Valve 2K 4002 1 2 3 4 5 6 7 8 A 28 18 21 g 10 21 1 1 6 2 L 5 3 8 29 B I B C D ppm d 11 16 17 12 15 14 13 LfdNr Stuck Benennung und Fertigmalle DIN Werkstoff Zeichnungsnummer Bemerkung f f E b z a d nderung Datum Name nderung Datum Name Datum Name Gehort zur Zeichnung Gezeichn 12 02 2007 Roj Gepr ft Narmen q Mafist ay 1 Ma e ohne et Material valve agabe nach ff Filenane DIN ISO 7168 1 2K 4002 mem Diese Zeichnung wurde mit CAD erstellt und mul mit CAD ge ndert werden 1 2 3 L
37. p Magic Flow 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 gear wheels Magic Flow Pair of gear wheels incl slide bearing bush ca 8 800 impulse liter Shaft volumeter Magic Flow Connecting cable volumeter Magic Flow Connecting cable 5m yellow not EEx Extension cable volumeter per meter alternatively yellow or blue Merchandise Group Options Magic Flow 2K 2006 EEx proof kit Magic Flow Conversion kit for Magic Flow includes 2 off EEx sensors for volumeter in exchange for standard sensors 1 off EEx solenoid valve 5m cable 2 off section switch amplifiers Page 45 of 66 2K 2007 Robot communication kit 8 off optoelectronic coupler inputs 8 of optoelectronic coupler outputs In top hat housing for connection to PLC bus cable length max approx Im 2K 2008 Transceiver kit 2 off transceiver units for PLC bus Magic Flow without cable for the connection of external PLC modules for a distance of more than one meter Recommended cable to connect the units CAT5 CAT6 network cable twisted pair shielded 2K 2026 Non ex remote control with recipe display additionally a transceiver kit 2K 2008 is required 2K 2047 Ex remote control category 2 with recipe display additionally a transceiver kit 2K 2008 is required 2K 2010 Pneumatic remote panel for Magic Flow 3 functi
38. p valve It is possible to deposit for each step in the flushing program whether the signal Dump Valve shall be activated The signal can then be used to activate a gun cleaning box or whether the cleaning shall be carried out via an external dump valve 7 Begin in the flushing program a loop can be programmed which in wraparound manner carries out certain steps 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 running see 7 UF 10 iw Key to store all modifications Page 24 of 66 Feb 13 1 3c 5 5 3 Valves Press the valve key in order to enter the manual control panel for the connected valves signal outputs optional and pressure regulator optional EXNECIETS 2 The keys 1 32 control the relevant valves For security reason one fluid valve only can be opened at the same time If you want to close all valves again press the key Valves OFF The keys S1 S8 control the special signals output board with 8 power outputs in 24VDC optionally available S1 Mixing OK S2 Ready S3 Flushing S4 Filling S5 Dump Valve S6 Filled S7 Alarm S8 HiFlow Press the key Signals OFF to turn off all outputs You can test the optionally available pressure adjustment kit with the analogue regulator With you will reduce the value by 0 1 bar with you will inc
39. rease the value by 0 1 bar With Analogue OFF you will reset the value to 0 0 bar Page 25 of 66 Feb 13 BE 5 5 4 System Settings In system settings important and security relating settings for the operation of the installation can be entered The correct setting of these parameters is of great importance to the finish result and the trouble free operation of the installation Filling in ml Filling Quantity On the one hand the filling quantity is important for the external signal Filling to which for example a signal light can be connected which indicates the operator that the filling procedure has not been finished On the other hand the filling quantity is needed to control the pot life After removal of twice as much filling quantity the pot life will be reset to start value Removal of twice as much filling quantity is necessary in order to prevent mixing of already reacting and fresh material in the installation and in the hoses Incremental Size The incremental size is necessary to control the accurate mixing of the materials The deposited value indicates the maximum interval between two hardener metering injections in milliliters Important this value has no influence on the quality of mixing It only serves the control function The installation itself tries to meter the hardener in smallest possible injections The cycle frequency Page 26 of 66 Feb 13 of the valve depends on overpressure of the hardener need
40. riod Start flushing procedure Page 43 of 66 Feb 13 8 Spare Parts and Options 8 1 Spare Parts and General Options Item No Description Merchandise Group Basic Installations Magic Flow 2K 2000 Magic Flow electronic 2 component mixing und metering installation electronic control cabinet 600 x 380 x 210 mm with touch screen pneumatic hydraulic control cabinet 600 x 700 x 210 mm equipped for 1 main color 1 hardener 2 flushing agents metering range 50 2000 ml min per component Compression proof up to 250 bar incl 1 static mixer 300 mm length 10x8 mm Finishing Brands Order No 2K 2000 2K 2001 Stand post aluminum profile construction for 2 C installation hight 1500 mm depth 400 mm control cabinets can be mounted with height adjustment 2K 2002 Wheels set 2 off guide rolls 75 mm antistatic with double block up brake completely mounted Merchandise Group Electronic Magic Flow 2K 2004 Expansion card for 8 solenoid valves slot card for control Magic Flow card will be pushed into the main board and delivers 8 digital 24V outputs to trigger solenoid valves Cards are addressable for the valves 1 8 9 16 17 24 or 25 32 maximum of 6 expansion cards can be integrated into the control 2K 2005 Signal output card output card with 8 off 24V outputs to trigger external signals e g Alarm Flushing Fill etc callipered power max approx 400mA per channel max 2000mA total Can be used to trigg
41. rting from date of initial operation latest 30 days after delivery Any other agreements must be drawn up in writing 2 General 2 1 Notes for the User The safety precautions and safety standards of this section have been compiled for your safety and in your own interest For safe operation it is necessary that the user reads and understands all of the technical and safety literature The user must be familiar with the function of the installation und must be aware of the hazards and risks that may occur with pressurized pumps hoses and equipment 2 2 General Safety Standards DONOT move operate maintain or service the installation before reading and understanding this service manual If you do have any doubt or problem contact your superior or our representative NEVER leave tools or other mechanical components in the installation if it is in operation or if it shall be started NEVER exceed the maximum pressure of the installation The maximum pressure of the installation is defined by the component with the lowest maximum pressure You will find the maximum pressure of the installation at the type plate When replacing components ALWAYS exercise care that the new parts comply with the technical data regarding material and maximum pressure ALWAYS ensure that the spray area is properly ventilated according to legal requirements The equipment must ONLY be operated by authorized and adequately trained personnel who
42. s reason do not try UNDER ANY CIRCUMSTANCES to speed up this process by pressing especially hard on the display Page 22 of 66 Feb 13 5 5 2 Administration of Flushing Press the flushing program key in order to enter the administration of flushing 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 Eh Eh aloe Walue Dimension Uume Loop Humber of n x L Im n 1 Actual flushing step which is being processed A flushing procedure may consist of up to 20 different steps Only those flushing steps will run in numerical order where values are deposited 2a 2b Flushing step advance flushing step return changes to previous respectively next flushing step which shall be processed 3 Valve number Number of the flushing valve which shall be opened in this step 4 Flushing value set point value of this step which must run so that the installation skips to the next step alternatively in ml or in sec see 5 5 Dimension Displays whether the actual flushing step will be done in milliliters or in seconds Fundamentally the cleaning of the installation in milliliters is process safer However a quantity collection is not sensible for steps which cause an air solvent flushing Therefore the dimension can be determined for each flushing step separately Page 23 of 66 Feb 13 6 Dum
43. schine Funktion Elektronische 2 bzw 3 Komponenten Misch und Dosieranlage Handelsname Magic Flow Typenbezeichnung 2K 2000 wurde entwickelt konstruiert und gefertigt in Ubereinstimmung mit den zuvor genannten Richtlinien Folgende harmonisierten Normen wurden angewandt DIN 60204 1 ZH 1 406 ZH 1 200 EN 50082 2 1993 EN 50082 2 1995 Hersteller Finishing Brands Germany GmbH Justus von Liebig Str 31 63218 Dietzenbach Deutschland Page 4 of 66 Feb 13 1 Identification Data 1 Introduction 1 1 Preface Dear Customer May we congratulate you for having purchased your new electronic Multi Component Installation Please be assured that design and fabrication of the installation have been carried out according to state of the art and with the intention of greatest possible user comfort highest safety level and selection of the best material May we point out that careful study and continued use of this manual will provide a better understanding of the equipment and process resulting in more efficient operation longer trouble free service and faster easier troubleshooting Please make sure that this installation must only be operated by adequately trained personnel For your safety also refer to the service manuals of peripheral equipment i e pumps guns and electrostatic equipment If you do have questions regarding the equipment please contact our distributors or us We will be pleased to help you 1 2 I
44. t incorrectly lt i STOP contra pot life 01 59 32 1 Tank size The value displays the capacity size indicated in liters for this container 2 Minimum level The programmed value displays from which tank level the alarm output will be switched on 3 Level indicator The value displays the actual material 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 optionally available 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 17 of 66 Feb 13 5 4 Flushing BNG alue Dimension Oump HEE Loop Humber oF nc Loops 1 Actual flushing step A flushing procedure may consist of up to 20 different steps All flushing steps for which values are deposited will be run in numerical order 2 To skip one flushing step If the actual flushing step shall be skipped press the key and skip to the next flushing step for which values are deposited 3 Valve number The actually opened flushing valve is displayed 4 Flushing value deposited set value of the flushing program alternatively in ml or in sec see 5 5 Dimension Displays whether the actual flushing step will be done in milliliters or in seconds Fundamentally the cleaning of the i
45. table 14 BSP to M16x1 5 2K 2160 Adjustable T screw connection M16x1 5 2K 2038 Adjustable L screw connection M16x1 5 Page 58 of 66 Feb 13 8 2 7 Touch Panel TOUCH PANEL 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 When switching on touch the panel until the following message appears touch adjustment Now 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 is available under article number 2K 2052 Alternatively e g in case of a glass breakage a replacement display can be obtained under the article number 2K 2052 REP Page 59 of 66 Feb 13 9 Installation Shut ff If the installation shall be shut off for a longer period of time the following steps must be carried out 1 Carry out at least one complete flushing procedure in order to remove mixed material from the installation Depressurize all fluid supply systems Open manually all connected valves via the relevant menu in order to relieve residual pressure Remove all supply hoses from the color change valves Connect the flushing agent supply system to each valve in succ
46. tered flushing procedure will run once for every previously filled gun During each run another extractor unit will be activated in order to ensure that every gun is flushed properly Page 19 of 66 Feb 13 5 5 Settings ALARM EVENTS SET DISPLAY LLOCH UPDRTE UPORTE In the Tool Menu all installation parameters can be set All settings can influence the mixture result and should therefore only be carried out by trained personnel or by service technicians There is also the possibility to protect all sub menus by passwords and to inform only selected persons see Codes Page 20 of 66 Feb 13 5 5 1 Recipes Press the recipe key in order to enter the recipe administration if necessary enter security code Flush 1 Press the key for the recipe number on top left to select the recipe to be modified 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 connected colors Use the chart on top right For the selected recipe a material valve can be allocated to each metering channel A B C and the material portion 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 4 portions and for B 1 portion are entered or whether the mixture ratio will b
47. up 1 Mutter CCV 3 Nut Spring rucks pring Ersatzteilsatz CC V 41 K2 Spare Part Kit CCW 41 K2 Ersatzteilsatz CCV 8 K2 Spare Part Kit CCV 8 K2 D cheibe CCV A S Washer Nadeldichtung CCV 8 Valve Needle Seal Material Einla 2 fach a NPT F Fluid Inlet 2 ports NPT F 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 484 1 Wird mit Ventil lose mitgeliefert Nicht ben tigt bei Farbzirkulation Shipped loose with valve Not used if material is recirculated Spanner Nut Retaining Ring Ring Retainer Poppet Seat Siem Blindstopfen SSP 1421 Pipe Plug In Reparatursatz KK 4841 enthalten Supplied in Repair Kit KK 4841 Ox 11 Page 50 of 66 Feb 13 Description Part No Draw No Remarks Supplier EEE Valve Body schaltanzeiger CCV 42 Valve Indicator Valve Cap Klebstoff mittlerer Festigkeit Loctite 242 An 2 Stellen auf Gewinde auftragen Binding Material medium strength grade Use on threads 2 places Bei Montage d nnen Film auf Bohrung und Manschette auftragen Leichtes Schmierfett Or lt 3 EH E s Light grease Apply a thin film of lubricant to bore amp cup at assembly Schl ssel nicht gezeichnet Spanner Tool not shown Ring Ring Retainer In Reparatursatz KK 4841 enthalten Supplied in Repair Kit KK 4841 Page 51 of 66 Fe
48. xing accuracy better than 1 according to calibration Volume flow according to design standard 0 05 2 l min Maximum operating pressure 10 bar standard version optional up to 250 bar versions with higher pressure are available on request Measurements Height 1600 mm incl rolls set and stand post Width 640 mm Depth 400 mm Page 64 of 66 Feb 13 Personal Notes Page 65 of 66 Feb 13 Finishing Brands UK Limited Finishing Brands Germany GmbH Surfaces et Finitions Ringwood Road Bournemouth Justus von Liebig Str 31 163 171 Av des Aur ats BH11 9LH England D 63128 Dietzenbach 26014 Valence cedex FRANCE Tel 44 0 12 02 57 1 1 11 Tel 49 0 60 74 403 1 Tel 33 4 75 75 27 00 Fax 44 0 12 02 57 34 88 Fax 49 0 60 74 403 300 Fax 33 4 75 75 27 59 E mail marketing uk finishingbrands eu E mail marketing de finishingbrands eu E mail marketing fr finishingbrands eu www finishingbrands eu Page 66 of 66 Feb 13
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