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INSTRUCTION MANUAL
ELECTRONIC MIXING MACHINE PU 3000
Manual : 1110 573.199.112
Date : 10/10/11 - Cancels : 14/12/10
Modif. : Update
TRANSLATION OF THE ORIGINAL MANUAL
Before assembly and start-up, please read and clearly understand all the
IMPORTANT
:
documents relating to this equipment (professional use only).
THE PICTURES AND DRAWINGS ARE NON CONTRACTUAL. WE RESERVE THE RIGHT TO MAKE CHANGES WITHOUT
PRIOR NOTICE.
KREMLIN REXSON
150, avenue de Stalingrad
93 245 - STAINS CEDEX – France
Téléphone : 33 (0)1 49 40 25 25
Fax : 33 (0)1 48 26 07 16
www.kremlin-rexson.com
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Summary of Contents for Kremlin-Rexson PU 3000
- Page 1 INSTRUCTION MANUAL ELECTRONIC MIXING MACHINE PU 3000 Manual : 1110 573.199.112 Date : 10/10/11 - Cancels : 14/12/10 Modif. : Update TRANSLATION OF THE ORIGINAL MANUAL Before assembly and start-up, please read and clearly understand all the IMPORTANT documents relating to this equipment (professional use only).
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Page 2: Table Of Contents
TABLE OF CONTENTS SAFETY INSTRUCTIONS ........................... 4 GENERAL SAFETY INSTRUCTIONS..................4 SPECIFIC SAFETY INSTRUCTIONS ..................4 ENVIRONMENT...........................5 DESCRIPTION ............................. 6 OPERATING DESCRIPTION........................8 FEATURES ..............................8 INSTALLATION ............................9 HANDLING...........................9 STORAGE............................9 ENVIRONMENT ON THE AREA ....................9 ... - Page 3 16. FEATURES - PU 3000 AIRMIX....................... 32 COMPOSITION .........................32 TECHNICAL FEATURES ......................32 SPECIFIC PARAMETERS......................32 17. DISASSEMBLY & REASSEMBLY - PU 3000 PNEUMATIC, PU 3000 AIRMIX ........33 MIXER............................33 PILOTED VALVES........................33 FLUID SECTION, MODEL 50 (BASE) (REFER TO DOC. 573.080.050) ........34 ...
- Page 4 ADDITIONAL DOCUMENTATIONS : Incorporation declaration and EC declaration of 578.013.130-UK conformity PU 3000 PNEUMATIC PU 3000 Pneumatic Pump - Assembly Doc. 573.404.050 Pneumatic motor, model 1500 (only for PU3000) Doc. 578.009.110 BASE fluid section, model 50 Doc. 573.080.050 CATA fluid section, model 50F Doc.
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Page 5: Safety Instructions
Dear Customer, You are the owner of our new PU 3000 mixing system and we would like to take this opportunity to thank you. Special care has been taken during all designing and manufacturing process to make sure your investment will provide full satisfaction. Non-compliance with instructions and precautions stated in this manual could reduce the equipment working life, resulting in operating problems and create unsafe conditions. -
Page 6: Environment
CAUTION : To prevent from any formation of gas and inflammable vapours, use paint whose flash point is the highest possible (refer to materials' safety instructions). Before cleaning or removing components of the equipment, it is compulsory : 1 - to shut off the air supply, 2 - to open the gun fluid circuit and depressurize the hoses, 3 - to switch off the machine electrical supply. -
Page 7: Description
2. DESCRIPTION The PU 3000 proportioning system is designed for applying two component solvent or water-based paints and lacquers. There are three versions available : - a pneumatic version (maximum pressure : 0-6 bar / 0-87 psi or 6-40 bar / 87-580 psi) - an AIRMIX... - Page 8 LCD screen. The PU 3000 continously saves data on the consumptions of base, catalyst and solvent as well as the total consumptions and the emissions of Volatile Organic Compounds (VOC) during the operation of the machine.
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Page 9: Operating Description
3. OPERATING DESCRIPTION The 2 BASE and CATALYST materials are sent to the mixing machine from 2 pumps. In production, as well as in regeneration, the machine injects a small volume of catalyst (P-6) in the base continuous flow. The PLC continuously checks the mixing ratio and if it notices a fault that it cannot correct, an alarm is activated. -
Page 10: Installation
5. INSTALLATION HANDLING The PU 3000 system with relevant weight and dimensions must be handled by appropriate means. Nota : The handling of the machine must be carried out by a qualified staff, in an appropriate space, correctly cleared to avoid any risks of fall or of crushing of people. -
Page 11: Description Of The Label Markings
DESCRIPTION OF THE LABEL MARKINGS The PU 3000 machine is fitted with 2 label markings : a plate on the control box and another one on the fluid equipment. Marking label on the control box Marking label on the frame (frame assembly located inside the spray booth ... -
Page 12: Installation Diagram
INSTALLATION DIAGRAM Potentially explosive area : area 1 (Z1) or area PTFE HP fluid hose 2 (Z2) (spray booth) Non explosive area (safe area) Automatic valves PU 3000 control box Mixer BASE pump Electrovalves CATALYST pump HP Fluid hose (not supplied) -
Page 13: Installation
INSTALLATION There are different ways to install the PU 3000 to answer to the majority of the installations. The control box of the PU 3000 mixing machine must be installed outside the spray booth in a safe area. -
Page 14: Connection Of The Control Box And Of The Fluid Frame
Install a fluid hose, model HP (high pressure) between the mixer outlet and the spray gun ( according to the pressures the pumps supply). Connect the air equipment of the PU 3000 to the pneumatic network with a conductive hose (minimum 16 mm / 5/8 dia). - Page 15 Unscrew the 3 air regulators before supplying air to the installation. Supply air to the PU 3000 (minimum 4 bar / 58 psi). Switch on the control box (switch located on the side of the box). When switching on the control box, a menu is displayed on the screen.
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Page 16: First Switching On
A line is visible when the PU 3000 is flushed. When switching on, the machine is waiting. The 'F1' menu corresponds to the shift to the production mode. There are five different menus : they enable to control the PU 3000. F1 : production... -
Page 17: First Placing Into Operation
During that first placing into operation, it is compulsory to have all the pumps into solvent as well as the machine to ensure the good quality of the fluid get by the PU 3000. The fluid pressure must not exceed 1 bar / 14.5 psi on the gauges. -
Page 18: Start Up Of The Machine
Nota : During that stage, you can not use the spray gun. When the mixing ratio checking is over, switch off the PU 3000 machine. Disconnect the air hose from the VP3 valve and connect it to the BASE valve. -
Page 19: Application Programming (F3)
9. APPLICATION PROGRAMMING (F3) To alter the parameters of the PU 3000, go to F3, then validate. To shift from a parameter to another, use . the arrows Select the parameter to alter. Depress the key , then the arrows to increase or decrease the value. -
Page 20: Parameters
PARAMETERS Parameters Description Factory adjustment Your adjustments Parameter of the password Mixing ratio parameter. Percentage of catalyst 50 % in the base, from 0,1% to 160% Parameters of the mixed fluid life time 30 min Minimum value : 1min ... -
Page 21: Validation Of The Initialization Mode
Number of thousands of cycles before preventive maintenance on the A pump 500 cyc Minimum value : 1 (i.e. 500 000 cycles) Maximum value : 9999 Number of thousands of cycles before preventive maintenance on the B pump 500 cyc ... -
Page 22: Production (F1)
You can also activate ESC during the fluid priming; we advice you not to start painting inmediately. In production, there are 3 main screen messages: The operator is spraying and the PU 3000 is operating correctly. The real mixing ratio is displayed on the screen. ... -
Page 23: Flushing (F2)
FLUSHING (F2) This menu is used for flushing. When you want to flush the machine, activate when you are on the F2 menu. After confirming via , the machine opens the solvent valve. The buzzer sounds intermittently. Check the solvent pump supply valve is open. A countdown begins : F2-9, then F2-8. - Page 24 Arborescence of the F4.CLr menu : Enables the user to reset the consumption of the A pump and the consumption of VOC activating the key ▲▼ Enables the user to reset the consumption of the B pump activating the key ...
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Page 25: Indications Of Operation Given By The Machine
10. INDICATIONS OF OPERATION GIVEN BY THE MACHINE INDICATIONS GIVEN BY THE LEDS Description Function Action Red LED Fault The machine stops Orange LED Working Function other than production (flushing, pot- life alarm …) Green LED Production Green + orange LED Waiting LED switched off Programming... -
Page 26: Maintenance
Flush when ending the work. SYNOPTIC info moteur B 230/115 V 10/14 / /S câble (long. 8m) info moteur A VP2B VP2A Nota : diagram of a pump, model PU 3000 Airmix KREMLIN REXSON Page 25 Manual : 573.199.112... -
Page 27: Maintenance Plan
MAINTENANCE PLAN The life duration of the different elements depends on the properties of the material used. The following maintenance plan is for information only and can not be taken into account when making a complaint. SUBSET ELEMENT OPERATION TO CARRY TIME PERIODICITY MACHINE TOOLS... -
Page 28: Troubleshooting
TROUBLESHOOTING For any intervention on the machine : - Flush the circuits, - Shut off the compressed air, - Depressurize the hoses by triggering the gun, - Shut off the electric supply. If a problem occurs during the machine operation, alarms will be displayed on the screen of the machine. Input to disable each alarm. -
Page 29: Proportion And Output According To The Ratio
MATERIAL FAULTS CHECKINGS Check if the valves are open : No : - Check air supply (minimum 4 bar / 58 psi), - Check the connection of the 25 pts cable, No fluid flows when passing into production or - Check the correct operating of the flushing mode. -
Page 30: Mixing Ratio
13. MIXING RATIO A : Base B : Catalyst B / A x 100 = X% Ex : A = 2.5 B = 1 1 / 2.5 x 100 = 40% 0.625 10.5 9.524 9.091 66.7 11.5 8.696 8.333 12.5 33.3 7.692... - Page 31 SPECIFICATIONS PU 3000 PUMP - model Pneumatic & model Airmix KREMLIN REXSON Page 30 Manual : 573.199.112...
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Page 32: Features - Pu 3000 Pneumatic
115V / 230V - 10W Air inlet connection F 3/4 BSP (air inlet valve) Fluid outlet connection (mixer) F 3/4 JIC The control box of the PU 3000 mixing machine must be installed outside the spray booth. SPECIFIC PARAMETERS Parameters... -
Page 33: Features - Pu 3000 Airmix
115V / 230V - 10W Air inlet connection F 3/4 BSP (air inlet valve) Fluid outlet connection (mixer) F 3/4 JIC The control box of the PU 3000 mixing machine must be installed outside the spray booth. SPECIFIC PARAMETERS Parameters... -
Page 34: Disassembly & Reassembly - Pu 3000 Pneumatic, Pu 3000 Airmix
17. DISASSEMBLY & REASSEMBLY - PU 3000 PNEUMATIC, PU 3000 AIRMIX CAUTION : Before any work is carried on the pump, stop the machine after carrying out flushing, shut off the compressed air supply and depressurize the circuits triggering the gun. -
Page 35: Fluid Section, Model 50 (Base) (Refer To Doc. 573.080.050)
FLUID SECTION, MODEL 50 (BASE) (REFER TO DOC. 573.080.050) Guards (air motor cover, coupling shields, connectors,…) have been designed for safe use of the equipment. The manufacturer will not be held responsible for bodily injury or failure and / or damage to property due to removal or partial removal of the guards. - Page 36 ASSEMBLY INSTRUCTIONS (FLUID SECTION, MODEL 50) Index Instruction Description Part number 'TECHNILUB' grease (10 ml) PTFE grease 560.440.101 WEICON AS1000 grease WEICON AS1000 grease box (1 kg / 2.204 lb) 560.420.005 Medium strength Loctite 577 Aneorobic Pipe sealant KREMLIN REXSON Page 35 Manual : 573.199.112...
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Page 37: Fluid Section, Model 50 F (Catalyst) (Refer To Doc. 573.114.050)
FLUID SECTION, MODEL 50 F (CATALYST) (REFER TO DOC. 573.114.050) Guards (air motor cover, coupling shields, connectors,…) have been designed for safe use of the equipment. The manufacturer will not be held responsible for bodily injury or failure and / or damage to property due to removal or partial removal of the guards. - Page 38 Before reassembling the different components : Clean the parts with the appropriate cleaning solvent, Install new seals if necessary, after having lubricated them with PTFE grease. Lubricate the piston and the inside of the cylinder to prevent from damaging the seals, Install new parts if necessary.
- Page 39 SPECIFICATIONS PU 3000 PUMP - model Airless KREMLIN REXSON Page 38 Manual : 573.199.112...
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Page 40: Features - Pu 3000 Airless
115V / 230V - 10W Air inlet connection F 3/4 BSP (air inlet valve) Fluid outlet connection (mixer) F 3/4 JIC The control box of the PU 3000 mixing machine must be installed outside the spray booth. SPECIFIC PARAMETERS Parameters... -
Page 41: Disassembly & Reassembly - Pu 3000 Airless
Replace the packing seal (36) or the air packing assembly. Nota : when changing the ASI 40 valve from the PU 3000 fluid equipment, take off the fittings from the spare valve delivered, then install it on the fluid equipment. -
Page 42: Fluid Section, Model Alto 50Cc (Base) (Refer To Doc. 573.395.050)
FLUID SECTION, MODEL ALTO 50CC (BASE) (REFER TO DOC. 573.395.050) WARNING! Before any action on the pump, shut off the compressed air supply and depressurize the systems by triggering the spray gun. Guards (air motor cover, coupling shields, connectors,…) have been designed for safe use of the equipment. - Page 43 Before intervening on the equipment : Clean the parts with the appropriate cleaning solvent, Install new seals if necessary, after having lubricated them with grease. Lubricate the piston and the inside of the cylinder to prevent from damaging the seals, Install new parts if necessary.
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