DÖRR EcoDose 2K Operating Manual
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DÖRR EcoDose 2K Operating Manual

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EcoDose 2K
Operating Manual
OPERATING MANUAL
MDR00003EN
Material number: N10100003V
Release :
Date :
10
25.05.2020
www.durr.com
LEADING IN PRODUCTION EFFICIENCY

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  • Page 1 LEADING IN PRODUCTION EFFICIENCY EcoDose 2K Operating Manual OPERATING MANUAL MDR00003EN Material number: N10100003V Release : Date : 25.05.2020 www.durr.com...
  • Page 2 TRANSLATION OF THE ORIGINAL INSTRUCTIONS Manufacturer: Dürr System AG Application Technology Carl-Benz Str. 34 74321 Bietigheim-Bissingen Germany Telephon: +49 7142 78-0 Internet: www.durr.com Revision Status Quality Assurance System is responsible to maintain updated this document in its last version applicable. Version / Changes Version of this document: 10 dated 25.05.2020 Story of version / changes:...
  • Page 3 The reproduction, distribution and utilization of this document as well as the communication of its contents to others without explicit authorization is prohibited. Offenders will be held liable for the payment of damages Operating Manual © Dürr Systems AG ED2K N10100003V – Operating Manual Rev10LD EN. docx Rev.10 –...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Introduction ....................How to Use this Document ..................Terminology ......................Explanation of Safety Notes and Signs ..............Technical Data ..................... Range of Application and Intended Use ............... Key Data ........................Version ........................Determination of the Ex Zones ................Associated Documents ...................
  • Page 5 System configuration....................Management of PLC alarms for consumable components ........ Operations ....................Overview controls ....................Operative modes...................... Visualization ......................Browsing windows ....................8.4.1 System page ....................8.4.2 Cycle program page ..................8.4.3 Parameters page ..................8.4.4 Pre-purge and purge cycle page ............... 8.4.5 Active alarm page ..................
  • Page 6 8.5.8 Parameters ....................8.5.9 Alarms windows ................... 8.5.9.1 Actual alarms ................... 8.5.9.2 Alarm history ................... Messages and alarm groups .................. External recipe mode ....................External control interface ..................8.8.1 Outputs to external control interface ............8.8.2 Inputs from external control interface ............Example interface flowchart ...................

  • Page 7: Introduction

    Introduction This document is intended for the assembly, operating and directing and maintenance personnel. Everyone implied in operation, maintenance and repair must have read and understood this document – especially the texts marked with the safety symbol. This document should always be at the disposal of personnel. Attached to this document there are drawings, parts lists, manuals of the main components that should be used for more information.
  • Page 8 It is assumed that before performing the operations therein described, the operator has fully understood the entire manual and knows its contents. The sole observance of safety notes is by no means sufficient. Dangers to life and limb The red safety note "Danger" indicates a high risk that will result in death or a severe injury D A N G E R Danger of lethal injuries...

  • Page 9: Technical Data

    According to type of flow meters used, are available two versions, with Coriolis flow meters and with Gear flow meters, each of them in high pressure or low pressure. EcoDose 2K was built exclusively for use in the field of surface finish or similar activities EcoDose should be installed, maintained and repaired only by persons who know the equipment very well and have been made aware about the dangers.
  • Page 10 (optional ) Gear Version Coriolis Version D A N G E R EcoDose 2K in “stand alone” version cannot be installed in areas with potentially explosive atmospheres, please see “separated version” for fluidic panel installation into Ex areas. Grounding The metal parts of the plants subject to contact with people who for lack of insulation or other causes may be energized, must be grounded.

  • Page 11: Key Data

    2.2 Key Data Coriolis version Gear version Dimensions in mm. Dimensions in mm. Product temperature 15 – 40 °C Air inlet pressure 5,5 - 8 bar Mixing ratio (variable) 1:0 - 30:1 20 bar max pressure in/out (low pressure version) max pressure in /out (high pressure version - gear) 200 bar 160 bar...

  • Page 12: Version

    2.3 Versions Gear Flow Control Gear Flow Meter A o B type 1 : 0,005-2 lt. 5cc-2000cc type 2 : 0,02-3 lt. 20cc-3000cc Volume Mixing ratio Range Range Flow Range Range Viscosity A CPS Viscosity B CPS 30cc / 1200 cc * 1:1 to 30:1 25-350 25-350...
  • Page 13 Coriolis Flow Control Coriolis Flow Meter A o B type 1 Volume Mixing ratio Range Range Flow Range Range Viscosity A CPS Viscosity B CPS 40cc / 3400cc 1:1 to 30:1 20-500 20-500 color change block valves : Low or high Pressure n.

  • Page 14: Determination Of The Ex Zones

    2.4 Determination of the Ex Zones Version : Stand Alone Connection paint master controller / robot / safety Not included into "ED2K scope of supply", to be supplied/installed by a different entity/scope. All hoses for paint supply and air supply to and from the machine are not included into the scope of supply.
  • Page 15 Version : Separate Connection paint master controller / robot / safety Not included into "ED2K scope of supply", to be supplied/installed by a different entity/scope. All hoses for paint supply and air supply to and from the machine are not included into the scope of supply. Flow control Color change valves Filter product...

  • Page 16: Associated Documents

    Besides the observance of safety instructions therein described, as far transport operations, installation, normal functioning maintenance are concerned, also refer to the instructions contained in the manuals of the equipment connected to EcoDose 2K For example: • Filter product • Pumping unit •...

  • Page 17: Normative Requirements

    2.6 Normative Requirements Below is the table with the directives and regulations for the complete machine and just for the Fluidic Panel : Complete machine declaration : Machinery Directive 2006/42/EC Low Voltage Directive 2014/35/EC Electromagnetic Compatibility Directive 2014 / 30 / CE Regulations: UNI EN ISO 12100:2010 assessment...

  • Page 18: Safety

    - personnel having knowledge of the possible dangers - personnel having knowledge of the applicable safety regulations. The installation, maintenance and repair of EcoDose 2k can only be carried out by experienced personnel [3]. An adequate advanced training or qualification of the personnel i has to be regularly performed.

  • Page 19: Use Of Tools In Ex Zones

    The customer must ensure that the operator’s tasks and responsibilities have been clearly defined. The customer must ensure that every operator has been informed and instructed about all dangers. The customer must provide the operator with the necessary protective equipment. Each operator must have been informed and instructed about safety functions and safety equipment.

  • Page 20: Basic Information On Safety Notes

    3.3 Basic Information on Safety Notes A T T E N T I O N General dangers relative to the plant where EcoDose 2K is going to be installed are not expressly referred to in this manual. The personnel must be informed by the customer and correspondingly trained on these dangers.

  • Page 21: Plate Data. (Example)

    3.6 Plate data Atex marking of Fluidic Panel: Operating Manual © Dürr Systems AG ED2K N10100003V – Operating Manual Rev10LD EN. docx Rev.10 – 25.05.2020...

  • Page 22: Transport And Storage

    Transport and Storage A T T E N T I O N The following operations can be performed only by adequately trained personnel. See chap. 3 of this manual C A U T I O N You must wear personal protective equipment Always wear the following equipment during assembly operations.

  • Page 23: Storage

    To remove EcoDose2K from the wooden crate, use the appropriate plank on the support frame. C A U T I O N Use a lift strap with a payload of at least 500 kg. 4.2 Storage The EcoDose2K must be stored in a closed space. Environmental conditions inside the storage place: - Temperature: 10 °C - 40 °C - Humidity: 35 % –...

  • Page 24: Description And Operation

    EcoDose 2K is a designed machine for dosing and mixing fluid components (typically bases and catalysts) according to pre-defined reports. The dosage is obtained within EcoDose 2K by controlling the quantity of each component, through the timed opening of pneumatic valves.
  • Page 25 0300033.CM.GE.02 rev.01 - ECODOSE 2K - CORIOLIS F. M. VERSION Available to be attached to this Manual Operating Manual © Dürr Systems AG ED2K N10100003V – Operating Manual Rev10LD EN. docx Rev.10 – 25.05.2020...

  • Page 26: Remote Magnetic Switch Panel

    5.1.1 Remote magnetic switch panel Optionally, you can equip the 'EcoDose 2K with a special remote control panel equipped with magnetic switches, placed outside the glass of the booth, which allows the operator, staying in the cabin, start the main controls, with a magnet.
  • Page 27 5.2 Operating system Compressed air is provided to EcoDose 2K from the compressed air network through the manual valve (5). Power supply equipments consist of a pressure generator (4), generally being a pump for the catalyst, basic components and the flushing products.
  • Page 28 The components (catalyst, paint base) are combined and premixed. The exact mixing takes place in the static mixer (9). When a gun (10) (Airmix too) is connected to EcoDose 2K the equipment is activated and controlled with an airflowmeter, that is installed in the control panel.

  • Page 29: Design Of The Modules

    5.3 Design of the Modules Electrical panel Scalance switch 5 doors ♦♦♦ Power supply 24 Vdc 24 Vdc safety device♦♦♦ Circuit breaker Relè ♦♦♦ Terminal board Safety barrier ♦♦♦ Indicative picture ♦♦♦ where provided For the full list of the electrical panel’s components, see the drawing: “Universal electrical cabinet - Parts list “attached to Chapter 11 of this manual Pneumatic panel Atomization air valves...

  • Page 30: Electrical Connections

    Assembly Instructions A T T E N T I O N The following operations can be performed only by adequately trained personnel. 1 electrical skilled man can perform properly connections described above. See chap. 3 of this manual. C A U T I O N You must wear personal protective equipment Always wear the following equipment during assembly operations.

  • Page 31: Pneumatic Connections

    Grounding The metal parts of the plants subject to contact with people who for lack of insulation or other causes may be energized, must be grounded. In this regard, on the base of the machine there is a point of contact identified by an adhesive (see drawing) for the connection with the network of general grounding of establishment.
  • Page 32 6.2.2 Pneumatic connection Compressed air general power supply (min. 5 bar - max. 8 bar) You must use the 1/2” gas F threaded connections. You must use a flexible pipe of at least Ø 1/2 " gas Connection of the atomization air to the guns You must use the 3/8”...

  • Page 33: Product Connection In

    6.3 Product connection IN EcoMCC3 low pressure color change valves max. 20 bar only used on circuit A (base) You must use 1/8 "gas female threaded connection ( 1 ) 1/8” gas female connections ( 2 ), are normally plugged, and they are used only in case of paint recirculation EcoValve7 20 color low pressure change valves...
  • Page 34 For the correct operation of the valves you must make sure that the tube (RIF.1) is always full of compatible lubricating oil with the products used. EcoDose 2K is delivered with empty tubes. The user must, before starting up the machine, fill the tubes with a suitable product to the products used Operating Manual ©...

  • Page 35: Product Connection Out

    6.4 Product connection OUT One Spray Gun option Double Spray Gun option Version without Low complete with Low complete with Low Pressure Regulator Flow pressure regulator flow pressure regulator flow Use 1/4 "gas 60° cone threaded connection W A R N I N G You must use suitable pipes to the operating pressure and to the products used.

  • Page 36: Commissioning

    Commissioning A T T E N T I O N The following operations can be performed only by adequately trained personnel. See chap. 3 of this manual. C A U T I O N You must wear personal protective equipment Always wear the following equipment during assembly operations.
  • Page 37 7.3 Alarms management on PLC for consumable components A T T E N T I O N The control system provides a warning message "MAXIMUM NUMBER OF PULSES ACHIEVED, PROVIDE MAINTENANCE" for consumable components EcoMCC3 20 EcoValve7 20 EcoMCC200 color change valves Color change valves color change valves low pressure...

  • Page 38: Operations

    Operation A T T E N T I O N The following operations can be performed only by adequately trained personnel. See chap. 3 of this manual. C A U T I O N You must wear personal protective equipment Always wear the following equipment during assembly operations.

  • Page 39: Operative Modes

    Operative modes EcoDose 2K can be operated in the following modes. Manual operation This operating mode is reserved to maintenance technicians (password level 3) with the only purpose to check the equipments efficiency, during maintenance operation. In manual mode valves can be operated individually.

  • Page 40: Visualization

    Visualization Descriptive header and footer In the visualization each page has the same header and menu on the left side. Header The header displays the following information Figure 2 header In the left outer side of the header the mode currently chosen is displayed through the following pictograms.

  • Page 41: System Page

    Left side menu The operating elements shown in the left side menu are used to navigate between the individual user interfaces (Configuration window, Spray window, Recipe window, Cycle program window, etc.). System page Spray page Spray data page Recipe page Cycle program page Parameter pages Purge program page...
  • Page 42 8.4 Browsing windows 8.4.1 System page System page Figure 3 System page Spray page Figure 4 Spray page Operating Manual © Dürr Systems AG ED2K N10100003V – Operating Manual Rev10LD EN. docx Rev.10 – 25.05.2020...
  • Page 43 Spray data page Figure 5 Spray data page Recipe page Figure 6 Recipe page Operating Manual © Dürr Systems AG ED2K N10100003V – Operating Manual Rev10LD EN. docx Rev.10 – 25.05.2020...
  • Page 44 8.4.2 Cycle program page Figure 7 Cycle program page 8.4.3 Parameters pages Figure 8 Parameters page 1 Operating Manual © Dürr Systems AG ED2K N10100003V – Operating Manual Rev10LD EN. docx Rev.10 – 25.05.2020...
  • Page 45 Figure 9 Parameters page 2 Figure 10 Parameters page 3 Operating Manual © Dürr Systems AG ED2K N10100003V – Operating Manual Rev10LD EN. docx Rev.10 – 25.05.2020...
  • Page 46 Figure 11 Parameters page 4 Figure 12 Parameters page 5 Operating Manual © Dürr Systems AG ED2K N10100003V – Operating Manual Rev10LD EN. docx Rev.10 – 25.05.2020...
  • Page 47 Valves operation number pages (button located in parameters page 1) Figure 13 Valves operations - page 1 Figure 14 Valves operations - page 2 Operating Manual © Dürr Systems AG ED2K N10100003V – Operating Manual Rev10LD EN. docx Rev.10 – 25.05.2020...

  • Page 48: Pre-Purge And Purge Cycle Page

    8.4.4 Pre-purge and purge cycle page Figure 15 Pre-purge and purge cycle page 8.4.5 Active alarm page Figure 16 Active alarm page Operating Manual © Dürr Systems AG ED2K N10100003V – Operating Manual Rev10LD EN. docx Rev.10 – 25.05.2020...

  • Page 49: Alarm History Page

    8.4.6 Alarm history page Figure 17 Alarm history page 8.4.7 Consumptions page (button located in spray data page) Figure 18 Consumption page Operating Manual © Dürr Systems AG ED2K N10100003V – Operating Manual Rev10LD EN. docx Rev.10 – 25.05.2020...

  • Page 50: External Control Interface Signal Page

    8.4.8 External control interface signal page Figure 19 External interface control signal page 8.4.9 Calibration data page Figure 20 External Calibration data page Operating Manual © Dürr Systems AG ED2K N10100003V – Operating Manual Rev10LD EN. docx Rev.10 – 25.05.2020...

  • Page 51: User Management Page

    8.4.10 User management page Figure 21 User management page 8.4.11 Reset passwords page Figure 22 Reset passwords page Operating Manual © Dürr Systems AG ED2K N10100003V – Operating Manual Rev10LD EN. docx Rev.10 – 25.05.2020...

  • Page 52: Settings Page

    8.4.12 Settings page Figure 23 IP settings page Operating Manual © Dürr Systems AG ED2K N10100003V – Operating Manual Rev10LD EN. docx Rev.10 – 25.05.2020...

  • Page 53: Description And Operation Of Each Visualization Window

    8.5 Description and operation of each visualization window 8.5.1 System page functions Figure 24 switch mode “System page” 8.5.1 .1 Switching the operating modes By tapping the mode symbol in the header, a sub-window opens, through which you can switch into different modes. This sub-window can be opened from the headers of all main windows.
  • Page 54 When the key “Recipe mode on/off” is green the system is in Recipe mode. In this mode the operator can change the recipe in use and start the cycle programs. Login with a level 3password, tap on the button “Recipe mode on/off“ to leave the Recipe mode and enter the Manual mode.

  • Page 55: Language Switching

    8.5.1.2 Language switching By tapping on “Select language” dialog box A list box opens and you can make your language choice. By tapping on the appropriate language in the list box, the selection is confirmed and the texts of all images and alarms are displayed in the selected language.

  • Page 56: User Administration

    8.5.1.3 User administration Level User Password Authorization - password entry - menu choices - language change Simple worker - start cycle programs - save consumption data to USB stick - change date and time - switch external recipe mode on/off Expert worker duerr12 - select active guns...
  • Page 57 Figure 26 Enter password page After confirming the password, the currently active user level is displayed. Figure 27 System page By tapping on the display of previously described user levels, the value will be reset to level zero. Operating Manual ©...

  • Page 58: Date And Time Setting

    8.5.1.4 Date and time settings Date and time fields can be entered after tapping on each field: In External recipe mode a specific command can be sent from an external controller to synchronize date and time. Figure 28 Date and time Operating Manual ©...

  • Page 59: Data Backup To Usb Storage

    8.5.1.5 Data backup to USB storage Using the dropdown menu “USB functions” you will be able to secure the following data on a USB stick or to transfer them from a USB stick to the internal flash of the controller. •...

  • Page 60: Usb Data Save/Load Operations

    8.5.1.6 USB Data Save/Load Operations Insert USB stick in the IF4 – USB port. Log-in with appropriate user level Select the action that you want to perform Push the button to execute the action A message will be displayed with the result of the operation: The message disappears automatically after five seconds.
  • Page 61 On the USB Stick are created: • “EcoDose2K_ConfigData\Configuration” after saving Configuration to USB device, • “EcoDose2K_ParamData\Parameters” after saving Parameters to USB device, • “EcoDose2K_PurgeData\PurgePrograms” after saving Purge Programs to USB device, • “EcoDose2K_RecipeData\Recipes” after saving Recipes to USB device, • “EcoDose2K_Consumptions\Consumptions.csv”...

  • Page 62: Screen Cleaning

    8.5.1.7 Screen cleaning The screen cleaning can be activated through the following key: The screen goes black for 15 seconds and all key functions are disabled. Figure 30 Screen cleaning Operating Manual © Dürr Systems AG ED2K N10100003V – Operating Manual Rev10LD EN. docx Rev.10 –...

  • Page 63: Change Passwords

    8.5.1.8 Change passwords “User management” key opens the menu where passwords can be changed. Only the highest user level (Level 3) has the authorization to change passwords. Figure 31 Page change password The level of the changed password (Level 1-3) will be selected in the “User level”...

  • Page 64: Reset Passwords

    8.5.1.9 Reset passwords This window, which can be accessed by pressing this key is used to reset user passwords. The confirmation key to reset the passwords will appear if the correct “PIN CODE” is entered. PIN CODE : eco-auc-axb-cyd Figure 33 Resetting all passwords Pressing the following button all passwords are reset to factory settings.

  • Page 65: Change Ip Address

    8.5.1.10 Change IP address Figure 34 System page Using the IF2 IP port connection, the display is connected to the controller. This address cannot be changed. IP Address: 192.168.102.100 Subnet Mask: 255.255.255.0 Using the IF3 IP port connection, the controller can be connected to an external controller.
  • Page 66 Here the required IP address can be entered, using the corresponding input fields. The input is activated through the “confirmation button The menu can be left through the “exit button” In the display field “IP IF3 address” the new IP address will be displayed. Figure 36 System page The IP address of the interfaces IF2 and IF3 can be in different sub-networks.

  • Page 67: Change Calibration Data

    8.5.1.11 Change calibration data Flowmeters need to be parameterized by entering the number of pulses generated for each liter of flowing material. This value can be figured out with a specific measure carried out in a specific cycle program. The number of impulses per liter, however, can be entered manually as described below, for both channel A and B.

  • Page 68: Lamp Test

    In the right bottom of the screen there are three other buttons: copy, paste and save. using this button you can copy temporarily a Copy button row of the table using this button you can replace a Paste button previously row line with another using this button you can save all the Save button changes...

  • Page 69: Cycle Programs - Recipe Selection

    8.5.2 Cycle programs – recipe selection Figure 38 Cycle programs – recipe selection In this window the hydraulic and pneumatic circuits are shown in a schematic form. The scheme can vary slightly according to the equipment installed on the machine. From this window, in recipe mode, each cycle program (“purge”, “load”, “long purge”, “calibration A”...
  • Page 70 Once the cycle is selected press the button to start the cycle. If the system is equipped with EcoCleaner M, the valves to pull the spray gun’s trigger in the flushing box are automatically activated. While a cycle program is running, the bar of the related gun is filled in green color, to show the progress of the cycle.
  • Page 71 Once you have selected the required calibration, the calibration pop-up window appears. The window is divided in three sections. In the first there is the selection of the recipe on which you want to perform the calibration. In the second section there are the available commands: •...
  • Page 72 In the second display “Required quantity” you must enter the amount of the product on which you want to perform the calibration, then press start the cycle program. The volume of product sprayed must be collected into a measuring cup. Once the calibration cycle program is ended without error, a confirmation key is shown at the bottom of the calibration popup window.

  • Page 73: System Status List

    8.5.2.2 System status list Purging cycle program “Purge” is running, the entire system is flushed. the entire system is free of paint residues. This status is displayed Purged when cycle program “Purge” is completed without error. Loading cycle program “Load” is running the system is loaded with a color.

  • Page 74: Recipe Selection

    8.5.2.4 Recipe selection To change recipe in use fill out the field “Requested recipe” with a recipe number, 1 in the example. Tap on the requested recipe field, a display will appear on the screen with a keyboard with which you can type the number of the recipe you want to use. After entering the required recipe number, you have to press the start recipe change.

  • Page 75: Spray - Valves

    8.5.3 Spray - valves Figure 39 Cycle programs – Spray page At the left side of the atomizer page are present the current process values and the status of the machine. Recipe n°: number of the recipe in use. number of the color valve of the recipe in use number of the hardener valve of the recipe in use Mix ratio the mixing ratio of the recipe in use...
  • Page 76 Valves color valve solvent valve for color YPL1 purge air valve hardener valve YV1/H solvent valve for hardener BZL1 atomizing air pressure gun 1 BZL2 atomizing air pressure gun 2 YG 1 selection valve gun 1 YG 2 selection valve gun 2 BFDS color pressure valve BFDS1...

  • Page 77: Manual Control Valves

    8.5.3.2 Valves manual control Requirement for manual control valves: • control voltage must be switched on • manual mode must be selected To toggle the valve status, open or closed, you must tap the valve symbol Valve closed. Valve opens with a touch Valve opened.

  • Page 78: Spray Data

    8.5.4 Spray data Figure 40 Spray data page page While the system is spraying the window displays: • the current flow in channel A (color channel) in ml/min • the current flow in channel B (hardener channel) in ml/min • the current flow of mixed material in ml/min •...

  • Page 79: Recipes Data

    8.5.5 Recipes data Figure 41 recipe page In this page all the recipes are listed and numbered from one to one hundred. Each recipe includes a set of parameters and a name that appears in a display at the top right. Color valve number Hardener valve number Mixing ratio: Color part for each catalyst part...

  • Page 80: Pre-Purge, Purge Program

    In the right center of the screen there are buttons that allows to scroll the recipes list: it’s possible to browse them one at a time, ten at a time or go to the first and to last directly. In the right bottom of the screen there are three other buttons: copy, paste and save.

  • Page 81: Pre-Purge

    8.5.6.1 Pre-purge purging sequence: first A then B or opposite T-V1 solvent time in seconds T-PL1 air time in seconds quantity of color solvent (channel A) in milliliter quantity of hardener solvent (channel B) in milliliter Phase 1: YV1 valve is opened for T-V1 seconds, then YPL1 valve is opened for T-PL1 seconds;...
  • Page 82 In the right center of the screen there are buttons that allows to scroll the recipes list: you can browse them one at a time, ten at a time or go to the first and to last directly. In the right bottom of the screen there are three other buttons: copy, paste and save.
  • Page 83 You can browse recipes to control the consumptions of color and hardener for each recipe. To reset the consumption data login with user level 1 or higher. Every display has a “reset” button to reset the counters. There is also a “reset all” button to set all the counters to zero at once. Consumption data can be saved on the flash memory of the controller in a csv file which is possible to access in read and write mode, with a FTP connection, connecting to the Ethernet port IF3 with the credentials.
  • Page 84 OFF [s] valve is closed too, with the delay here specified. Default value 4 [s] If the EcoDose 2K supplies an automatic machine, set this option as YES. In this case automatic POT LIFE purge is allowed without AUTOMATIC MACHINE checking signals from gun-flushing box;...
  • Page 85 Used when the EcoDose 2K supplies an automatic machine and is equipped with a valve to control the guns’ needle. Choosing YES the Needle external actuation needle valve is opened also while spraying, Yes/No controlled by the external signal commands needle G1 or needle G2.
  • Page 86 After the loading cycle is finished the atomizing air is enabled with the delay here specified. This parameter is useful when the system is not equipped with EcoGunCleaner DELAY SPRAY ON [s] system equipped with EcoGunCleaner M, to be the atomizing air enabled after the time above here specified, the gun must be out of the EcoGunCleaner M and the cleaner box cover closed.
  • Page 87 Figure 46 Parameters page 3 HOSES SIZE Here is set the internal hose diameter, default value 6 [mm], and the hoses length, default value 7 [m]. Accordingly the hose volume is calculated in ml. Figure 47 Parameters page 4 Operating Manual ©...
  • Page 88 In order to keep YF color valve always open during the DELAY VALVE YF catalyst injection, it can be kept opened for a short time (A) OFF [ms] here specified, even when there is a surplus of color in the A/B mixing ratio. Default value 300 [ms] In order to reduce the number of operations (frequency) DELAY VALVE YH of the catalyst valve, it can be kept opened for a short...

  • Page 89: Consumption

    At the time here indicated the daily quantity consumed of solvents, colors and catalysts for each recipe, is saved in a CSV format file on the flash memory of the controller, REGISTER accessible by FTP connection. The saved file name is CONSUMPTION composed of the pair of characters written in the name TIME name-h:m...

  • Page 90: Parameters

    Figure 48 Parameters page 5 Only for system equipped with Coriolis flowmeter While spraying the temperature of color and TEMPERATURE ALARM catalyst are controlled. If the values of the THRESHOLDS [C°], DELAY temperature are consistently out of the intervals ALARM TEMPERATURE [s] here specified, after the time specified in DELAY ALARM TEMPERATURE, an alarm is raised.
  • Page 91 From the Parameter page SET UP 1 press the key to access the valves and flowmeter wear counters Figure 49 Valves operations - page 1 Figure 50 Valves operations - page 2 In order to reset the counters, you must log in with user level 3 and press the specific reset keys.

  • Page 92: Alarms Windows

    8.5.9 Alarms windows By pressing the alarm line you can open the alarm window. There are two alarms windows: active alarms and alarms history Press the button at the page footer to toggle the windows view: Actual alarms Alarm history 8.5.9.1 Actual alarms In this page are displayed all currently pending alarms and warnings.

  • Page 93: Alarm History

    8.5.9.2 Alarm history Figure 52 Alarm history page Column 1 number of alarm group Column 2 number of alarm within the alarm group Column 3 alarm text Column 4 date and time of the alarm event Alarm history records up to 1000 alarms. Use the key to empty the buffer.

  • Page 94: Messages And Alarm Groups

    8.6 Messages and alarm groups Group 0: System messages Alarm number Alarm Acknowledged all Bypassed all System init Cannot read alarm data Group 1: Process alarms Alarm number Alarm External recipe out of range Component A is not flowing Component B is not flowing Leakage valve channel A Leakage valve channel B Air supply pressure too low...
  • Page 95 External recipe the recipe number from the external controller is null or out of range beyond the maximum recipe number. Possible cause: after YF or YV1 and YG1/YG2 valves (when present)are opened and the spray gun is open, no impulses are measured by the flowmeter. Fault elimination: you must trigger the gun into waiting time flow control until the product is delivered.
  • Page 96 Possible cause: the POT-LIFE is expired POT life alarm Fault elimination. Purge the equipment to reset the alarm. Possible cause: for the selected recipe, calibration factors are Calibration not yet defined. factor (A or B ) Fault elimination: you must login as user level 3 and enter the less or equal to right values in the calibration table;...
  • Page 97 Analog input Possible cause : wrong analog signal of temperature from temperature A PLC analog input card only with Fault elimination: it requires maintenance intervention to Coriolis check the electrical connections flowmeter Possible cause : while spraying the temperature of the fluid Temperature A component in channel A is beyond the limits assigned in out of range only...
  • Page 98 Group 3: Hardware alarms Alarm number Alarm Festo valve module CTEU-CO not OK Card X20AI2322 not OK Card X20AO4622 not OK Profibus EcoPUC A RA BUS not OK No heart beat from external control Wrong serial number. Use the right configuration file All the hardware alarms require a maintenance personnel intervention to check the electrical components status and their connections Group 4: General system alarms...
  • Page 99 Error in program initialization routine Error in recipes initialization Possible cause : when powered, the PLC loads all the working routine data: cycle program, recipes, configuration, parameters and consumption from files in the memory storage area. If the Error in operation is unsuccessful this alarm is set.
  • Page 100 Possible cause: when powered, the PLC loads all the working data. If the operation is unsuccessful this alarm is set. Error in global Fault elimination: try to restore the missing data from a initialization previous backup saved on a USB memory stick. See the manual routines specific section.
  • Page 101 Possible Cause: There was an error during the daily process of writing data consumption on the flash memory accessible via Error saving FTP. Fault elimination : check the label name (couple of letters) to consumption of the saved data files (see parameter section 4 page settings). flash Check that the flash is present consumption folder, path F: \ Consumption \ where the file is saved.
  • Page 102 Alarm number Alarm YPL1 valve has been activated too many times, provide for maintenance YV1H valve has been activated too many times, provide for maintenance YG1 valve has been activated too many times, provide for maintenance YG2 valve has been activated too many times, provide for maintenance Max pulse amount reached on channel A, provide for maintenance...

  • Page 103: External Recipe Mode

    8.7 External recipe mode From Switch mode window, you can open the external recipe mode window by touching this button Figure 53 External interface control signal page This page summarizes input and output signals that are received from the external plc when the system is in “External recipe mode”. The window contains: •...

  • Page 104: External Control Interface

    8.8 External control interface 8.8.1 Outputs to external control interface OUTPUT TO EXTERNAL CONTROLLER Telegram Counter. It has to be copied to iTelCount AckTelCounter on the remote controller Alarm group information byte 0/1 (global iAlarmGrpIfoGlb1 alarm) Alarm group information byte 2/3 (global iAlarmGrpIfoGlb2 alarm) Alarm group information byte 0/1...
  • Page 105 30.0 iActualSetAtomizz_G2 Actual set atomizing air Gun 2 mbar 32.0 iActualSetColPress_G1 Actual set out pressure Gun 1 mbar 34.0 iActualSetColPress_G2 Actual set out pressure Gun 2 mbar 36.0 iColorFlow Actual color flow P1 And Or P2 [ml/min] Consumption color spray cycle in progress 38.0 iConsA [ml]...
  • Page 106 48.0 iSpare_48 50.0 iSpare_50 52.0 iSpare_52 54.0 iSpare_54 56.0 iSpare_56 58.0 iSpare_58 60.0 iSpare_60 62.0 mPurgeRun BOOL Program Purge is active 62.1 mLoadRun BOOL Program Load is active 62.2 mLongPurgeRun BOOL Program Long Purge is active 62.3 mPurgeNecessary BOOL Purge is necessary for the new recipe 62.4 mLoadNecessary BOOL...

  • Page 107: Inputs From External Control Interface

    8.8.2 Input from external control interface INPUT FROM EXTERNAL CONTROLLER iAckTelCount Acknowledge telegram counter => Ext iDateYear Date year => Ext bDateMonth BYTE Date month => Ext bDateDay BYTE Date day => Ext bTimeHours BYTE Time hours => Ext bTimeMinutes BYTE Time minutes =>...
  • Page 108 34.0 iSetColorFlow Set point color flow [ml/min] 36.0 iSpareO_36 38.0 iSpareO_38 40.0 iSpareO_40 42.0 iSpareO_42 44.0 iSpareO_44 46.0 iSpareO_46 48.0 iSpareO_48 50.0 iSpareO_50 52.0 iSpareO_52 54.0 iSpareO_54 56.0 iSpareO_56 58.0 iSpareO_58 60.0 iSpareO_60 62.0 mStartPurge BOOL Start Purge 62.1 mStartLoad BOOL Start Load 62.2...
  • Page 109 65.4 mSpareO_65_4 BOOL 65.5 mSpareO_65_5 BOOL 65.6 mSpareO_65_6 BOOL 65.7 mSpareO_65_7 BOOL 8.9 External interface flowchart Example: recipe selection from 1 to 100 Timing Diagram external control interface Example: On or Off External command Off allowed when the station is purged Example: consumption measure Operating Manual ©...
  • Page 110 Example: life signal of telegram counter Example: abort active cycle program Example: set date and time Operating Manual © Dürr Systems AG ED2K N10100003V – Operating Manual Rev10LD EN. docx Rev.10 – 25.05.2020...

  • Page 111: Udp Connection Ecodose And External Control

    8.10 UDP connection EcoDose and external control To use external recipe mode it must be connected to the master controller through an UDP connection with the “EcoDose control”. To connect the IF3 interface the X20CP1381 B&R module must be used. On EcoDose control a UDP server is programmed, the corresponding external control must be programmed to connect a UDP client.

  • Page 112: Closed Loop Flow Regulation

    8.11 Closed loop flow regulation On a system with one spray gun, equipped with a flow modulating valve, can be activated, when available, a closed loop flow control. In the parameter page SETUP 4 activate, when available, the flow control option ”...
  • Page 113 Regulator page Figure 57 flow regulation automatic mode This page shows on the left the actual recipe in use, the value of the set point in [ml/min], and on the right, the system status, the value of the regulator output in percentage and in bar, the current measured value of the flow.
  • Page 114 Even if in the parameters setting the system is configured as closed loop, operating the regulator in manual mode, the system can be controlled while spraying as if it were regulated in pressure. Press on the key to access the recipe regulation data later described. Figure 59 recipe page –...
  • Page 115 Regulation table data In this table for each recipe is assigned a table of couples of values (regulator output percentage and corresponding flow) which should cover the working range of the recipe. After a recipe is loaded, these values of the output in percentage are taken as initial value of the output, then, while spraying, a PI algorithm will control the output regulator and therefore the flow.
  • Page 116 While filling out the table, write in the column T [C°] the temperature shown on the screen, measured by the Coriolis flow meters. While spraying at different temperatures, the calculated values of the output are corrected adding a ∆ term obtained multiplying the difference in temperature between the value in the table and the actual temperature for the coefficient K.
  • Page 117 Write in the recipe the output percentages of the regulator you want to measure the corresponding flow, set the output regulator in manual mode and press the key An automatic procedure is carried out where, the sequence of the set points written in the recipe is assigned to the output, and the corresponding values of the measured flow saved in the recipe regulation table.
  • Page 118 In the regulation page, press the button to open the graphic page, where are represented the values of the set point, the current flow, and the regulator output. You can zoom the graph by changing the parameters as described below. Regulation parameters In the regulation page, press the button to open the page of...
  • Page 119 Set this value at the lowest limit of the regulator output in percentage, which let the material pass through the Regulator lower spray gun; this avoid the regulator output gets stuck at limit such a low value doesn’t let the material pass. Default value 20% If air is sprayed with the gun, use this parameter to avoid the regulator output rises while the gun trigger is...
  • Page 120 External interface signal Figure 67 flow regulation – External interface control signal page In external recipe mode when the option “closed loop” is active, flow can be controlled through the signal interface in the variable Set Color flow. If the value of Set color flow is zero, the flow set point value is taken from the actual recipe in use.

  • Page 121: Remote Magnetic Switch Panel

    8.12 Remote magnetic switch panel The system can be equipped with a remote magnetic switch panel, separated from an Ex hazardous area by a glass wall. The operator, staying in the paint booth, can activate the main commands with a magnet. 8.12.1 Available commands The available commands are: to start a purging cycle.

  • Page 122: Recipe Change + / - And Confirm

    8.12.2 Recipe change + / - and confirm When the system is purged the recipe in use can be changed. The panel shows in the lower row the actual recipe number. The panel shows in the upper row the requested recipe number. Put the magnet in front of the sensors + or - and hold it in place for a short time, to increase or decrease the required recipe number.

  • Page 123: Remote Ecopuc A Ra Bus Panel

    The system can be equipped with the remote panel EcoPUC A RA BUS can be used Ex hazardous. The operator, staying in the paint booth, can activate the main commands pressing the keys on the EcoPUC A RA BUS which is connected with a cable to the EcoDose 2K controller. 8.13.1 Main menu...
  • Page 124 EcoDose 2k Color change status undefined, flushed, ready Alarm group EcoDose 2K to the alarms are associated codes, 000 means no alarm present. The red led on EcoPUC A RA BUS when an alarm is active is blinking every second...

  • Page 125: Menu Nominal Parameters

    8.13.1.2 Menu nominal parameters This menu is used to run commands on EcoDose 2K Press the key OK to enter the menu choices. Purging Press the keys up or down until you reach the flush request window Press the keys OK, the dashed line starts blinking Press the arrow up key to start the purging cycle The sign start is visualized.
  • Page 126 Loading Press the keys up or down arrow until you reach the fill request window Start or stop the loading cycle as described for the purging cycle. Recipe change Press the arrow up or down key until you reach the recipe change request window.

  • Page 127: Maintenance

    Maintenance A T T E N T I O N The following operations can be performed only by adequately trained personnel. See chap. 3 of this manual. C A U T I O N You must wear personal protective equipment. Always wear the following equipment during assembly operations.
  • Page 128 In particular, check the correct tightening of terminal screws. image indicative The EcoDose 2K PLC usually does not need any maintenance. The EcoDose 2K PLC is provided by a flash memory and does not need the installation of a buffer battery. Operating Manual ©...

  • Page 129: Fluidic Panel

    Fluidic panel COMPLETE “FLUIDIC PANEL” Gear version Coriolis version Daily inspect fluidic panel for visible damage. C.C. VALVES EcoMCC200 EcoValve7 20 EcoMCC3 C.c valves should be inspected periodically following the manufacturer's instructions (see Chapter 11 documents). The valve activity is controlled by the PLC, and if the number of switching operations carried out exceeds the programmed value, the display shows the following message: "MAXIMUM NUMBER OF PULSES ACHIEVED, PROVIDE MAINTENANCE".
  • Page 130 “CORIOLIS” FLOWMETER “Coriolis”mass flowmeters do not need any maintenance in addition to the normal calibration tests to ensure the suitable conditions. “GEAR” FLOWMETER For “Gear” flowmeters, if a measurement cell is not used for a long period, it must be washed with a suitable solvent. The washing is particularly important for measuring instruments, since the products release particles that can stick to the gear wheels.
  • Page 131 “GEAR FILTER” (only for versions with gear Flowmeter) Daily remove the filter, clean the cartridge or replace if necessary. For the model, see drawing mixing panel attached to chapter 11 of this manual EXCLUSION “GEAR FILTER” (only for versions with gear Flowmeter) If there should be the need of removing one or both “GEAR FILTER”...

  • Page 132: Parts List

    Parts List Available Drawings drawings n. rev. description EcoDose 2K general assembly - Gear flowmeter 0300033.CM.GE.01 version EcoDose 2K general assembly - Coriolis flowmeter 0300033.CM.GE.02 version 0300033.DT.GE.01 Universal fluidic panel_Gear flowmeter_HP 0300033.DT.GE.02 Universal fluidic panel_Gear flowmeter_LP_1Cat 0300033.DT.GE.03 Universal fluidic panel_Gear flowmeter_LP_3Cat 0300033.DT.GE.04...

  • Page 133: Available Documents

    Available Documents Documentation of vital components Supplier Description Model Code Endress + Hauser Coriolis flow meter Promass 80 W07020175 Gear flow meter ZHM 01/1 W07020134 0,005-2 l/min. Gear flow meter ZHM 01/2 W07020133 0,02-3 l/min. Low Pressure EcoFlow LPF P 7 N26010101 Regulator Flow Valves CC...
  • Page 134 Contacts & Hotline For any question or further technical information, please contact your dealer or sales partner. Operating Manual © Dürr Systems AG ED2K N10100003V – Operating Manual Rev10LD EN. docx Rev.10 – 25.05.2020...

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