DÖRR EcoDose 3K Operating Manual
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DÖRR EcoDose 3K Operating Manual

DÖRR EcoDose 3K Operating Manual

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EcoDose 3K
Operating Manual
1
Operating Manual
ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx
OPERATING MANUAL
EcoDose 3K
MDR00005EN
Material number: N10110001V
Release :
Date :
LEADING IN PRODUCTION EFFICIENCY
02
03.07.2020
© Dürr Systems AG
Rev.02 – 03.07.2020

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Summary of Contents for DÖRR EcoDose 3K

  • Page 1 LEADING IN PRODUCTION EFFICIENCY EcoDose 3K Operating Manual OPERATING MANUAL EcoDose 3K MDR00005EN Material number: N10110001V Release : Date : 03.07.2020 Operating Manual © Dürr Systems AG ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx Rev.02 – 03.07.2020...
  • Page 2 LEADING IN PRODUCTION EFFICIENCY TRANSLATION OF THE ORIGINAL INSTRUCTIONS Manufacturer: Dürr System AG Application Technology Carl-Benz Str. 34 74321 Bietigheim-Bissingen Germany Telephone: +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: 02 dated 03.07.2020 Story of version / changes:...

  • Page 3: Table Of Contents

    LEADING IN PRODUCTION EFFICIENCY TABLE OF CONTENTS Introduction............................6 How to Use this Document ...................... 6 Terminology ..........................6 Explanation of Safety Notes and Symbols ................7 Technical Data ..........................8 Range of Application and Intended Use .................. 8 Key Data ..........................9 Version ..........................
  • Page 4 LEADING IN PRODUCTION EFFICIENCY Operative modes ........................35 Visualization .......................... 37 Browsing windows ......................... 39 8.4.1 System page ........................39 8.4.2 Cycle program page ......................41 8.4.3 Parameters pages ......................41 8.4.4 Pre-purge and purge cycle page ..................45 8.4.5 Active alarm page ......................
  • Page 5 LEADING IN PRODUCTION EFFICIENCY 8.12.3 Pot life lamp ......................... 114 Maintenance ..........................115 Control panel ........................116 Fluidic panel ........................117 Parts List ..........................120 10.1 Drawings ..........................120 Attached documents ........................ 121 Contacts & Hotline ........................121 Operating Manual ©...

  • Page 6: Introduction

    LEADING IN PRODUCTION EFFICIENCY 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.

  • Page 7: Explanation Of Safety Notes And Symbols

    LEADING IN PRODUCTION EFFICIENCY 1.3 Explanation of Safety Notes and Symbols In this manual, symbols and signal words are used to indicate specific dangers. Symbols are integrated with a text. This text describes the danger and explains how to avoid it. Furthermore, the necessary precautions are specified.

  • Page 8: Technical Data

    Technical Data 2.1 Range of Application and Intended Use EcoDose 3K was built exclusively for use in the field of surface finish or similar activities. EcoDose 3K should be installed, maintained and repaired only by persons who know the equipment very well and have been made aware about the dangers.

  • Page 9: Key Data

    LEADING IN PRODUCTION EFFICIENCY 2.2 Key Data Dimensions in mm. Dimensions in mm. Coriolis version Gear version Product temperature min 15°C max 40°C Air inlet pressure 5,5 a 8 bar Mixing ratio (variable) da 1:0 a 30:1 Max. pressure in/out (with low pressure c. c. valves) 20 bar Max.

  • Page 10: Version

    LEADING IN PRODUCTION EFFICIENCY 2.3 Version Gear Flow Control Gear Flowmeter A,B or C type 1 : 0,005-2 lt. 5cc-2000cc type 2 : 0,02-3 lt. 20cc-3000cc Range Volume Mixing ratio Range Viscosity B - C Viscosity A CPS Flow Range Range 30cc / 1200 cc * 1:1 to 30:1...
  • Page 11 LEADING IN PRODUCTION EFFICIENCY Coriolis Flow Control Coriolis Flowmeter A,B or C type 1 Volume Mixing ratio Range Range Flow Range Range Viscosity A CPS Viscosity B - C CPS 40cc / 3400cc 1:1 to 30:1 20-500 20-500 Color change block valves Low or high Pressure n.

  • Page 12: Determination Of The Ex Zones

    LEADING IN PRODUCTION EFFICIENCY 2.4 Determination of the Ex Zones Option : Stand Alone Flow control Air manifold Color change valves Air filter Filter product Static Mixer Pumping unit Spray gun Manual valve EcoGun Cleaner M Remote magnetic switch panel Air regulator (optional) A T T E N T I O N...
  • Page 13 LEADING IN PRODUCTION EFFICIENCY Option : Separated Flow control Air manifold Color change valves Air filter Filter product Static Mixer Pumping unit Spray gun Manual valve EcoGun Cleaner M Remote magnetic switch panel Air regulator (optional) A T T E N T I O N During normal operation, an explosive atmosphere is present only inside the spray booth Operating Manual...

  • Page 14: Associated Documents

    Besides the observance of safety instructions therein described, as far as transport operations, installation, normal functioning and maintenance are concerned, also refer to the instructions contained in the manuals of the equipment connected to EcoDose 3K For example: Filter product...

  • Page 15: Plate Data

    LEADING IN PRODUCTION EFFICIENCY 2.6 Plate data Atex marking of Fluidic Panel: Operating Manual © Dürr Systems AG ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx Rev.02 – 03.07.2020...

  • Page 16: Normative Requirements

    LEADING IN PRODUCTION EFFICIENCY 2.7 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 Voltag Directive2014/35/EC Electromagnetic Compatibility Directive 2014 / 30 / CE Regulations: UNI EN ISO 12100:2010 Safety of machinery- General principles for design- Risk...

  • Page 17: Safety

    The installation, maintenance and repair of EcoDose 3K 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 18: Use Of Tools In Ex Zones

    3.2.1 Basic Information on Safety Notes A T T E N T I O N General dangers relative to the plant where EcoDose 3K 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 19: Special Safety Notes

    LEADING IN PRODUCTION EFFICIENCY 3.3.1 Special Safety Notes Before performing maintenance and repairs you must make sure that EcoDose 3K does not contain any residual pressure (air and product). W A R N I N G Danger due to spraying or splashing material! Potential chemical burns of the skin due to material spurting from defective paint pipes and color changers.

  • Page 20: Transport And Storage

    You must wear personal protective equipment Always wear the following equipment during assembly operations. 4.1 Transport Normally the EcoDose 3K is shipped in a wooden crate. The wooden crate is made to be easily transported on pallet trucks. image indicative Operating Manual ©...

  • Page 21: Storage

    LEADING IN PRODUCTION EFFICIENCY To remove EcoDose 3K 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 EcoDose 3K must be stored in a closed space.

  • Page 22: Description And Operation

    Description and operation 5.1 General Description EcoDose 3K is a designed machine for dosing and mixing fluid components (typically bases and catalysts) according to pre-defined ratios. The dosage is obtained within EcoDose 3K by controlling the quantity of each component, through the timed opening of pneumatic valves.

  • Page 23: Remote Magnetic Switch Panel

    5.1.1 Remote magnetic switch panel Optionally, you can equip the EcoDose 3K 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 24: Operating System

    LEADING IN PRODUCTION EFFICIENCY 5.2 Operating system image indicative Compressed air is provided to EcoDose 3K 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 25 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 3K the equipment is activated and controlled with an air flowmeter, that is installed in the control panel.

  • Page 26: Design Of The Modules

    LEADING IN PRODUCTION EFFICIENCY 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 Available to be attached to this Manual Pneumatic panel Atomization air valves...

  • Page 27: Assembly Instructions

    LEADING IN PRODUCTION EFFICIENCY Assembly Instructions 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 28: Pneumatic Connections

    LEADING IN PRODUCTION EFFICIENCY 6.2 Pneumatic Connections 6.2.1 Compressed air specifications Air quality must be DIN ISO 8573-1 Class 1-3-1 (water-oil particles). PARTICLES Class Max. Ø particles (1) Max. concentration (2) 0,1 micron 0,1 mg/m³ 1 micron 1 mg/m³ 5 micron 5 mg/m³...

  • Page 29: Pneumatic Connection

    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” gas F threaded connections on the back of EcoDose 3K Connection to EcoGun Cleaner M...

  • Page 30: Product Connection In

    LEADING IN PRODUCTION EFFICIENCY 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.
  • Page 31 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 3K is delivered with empty tubes. The user must, before starting up the machine, fill the tubes with a suitable product to the products used.

  • Page 32: Product Connection Out

    LEADING IN PRODUCTION EFFICIENCY 6.4 Product connection OUT Double Spray One Spray Gun Version without Gun option option complete Low Pressure complete with with Low pressure Regulator Flow Low pressure regulator flow 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 33: Commissioning

    Always wear the following equipment during assembly operations. 7.1 Starting EcoDose 3K has been tested by the manufacturer, however before the first start-up, you must: ensure that you have complied with all the activities described in chap. 6 check that all compressed air and product in / out connections are correctly tight.

  • Page 34: Alarms Management On Plc For Consumable Components

    For the correct functioning of the apparatus, these parameters must be calibrated depending on the specific application chosen. The initial settings on EcoDose 3K are absolutely indicative, and they do not determine any definition of the guarantees. Pre-set values are indicative and they refer to tests performed with Mesamol oil.

  • Page 35: Operation

    Illuminated red pushbutton: „Control voltage“: Turns off the system and lights up when there is an alarm. Illuminated green pushbutton „Control voltage“: Turns on the system Operator terminal: visualization for operating and monitoring EcoDose 3K Pressure switch „Emergency stop“ shutdown of the plant in an emergency situation 8.2 Operative modes EcoDose 3K can be operated in the following modes.
  • Page 36 LEADING IN PRODUCTION EFFICIENCY Manual operation This operating mode is reserved to maintenance technicians (password level 3) with the only purpose to check the equipment efficiency, during maintenance operation. In manual mode valves can be operated individually. Interlocks do not allow the opening of more than one valve at the time in the same channel, however valves have to be opened with caution and the system finally purged.

  • Page 37: Visualization

    LEADING IN PRODUCTION EFFICIENCY 8.3 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 38 LEADING IN PRODUCTION EFFICIENCY 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...

  • Page 39: Browsing Windows

    LEADING IN PRODUCTION EFFICIENCY 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 ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx Rev.02 – 03.07.2020...
  • Page 40 LEADING IN PRODUCTION EFFICIENCY Spray data page Figure 5 Spray data page Recipe page Figure 6 Recipe page Operating Manual © Dürr Systems AG ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx Rev.02 – 03.07.2020...

  • Page 41: Cycle Program Page

    LEADING IN PRODUCTION EFFICIENCY 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 ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx Rev.02 – 03.07.2020...
  • Page 42 LEADING IN PRODUCTION EFFICIENCY Figure 9 Parameters page 2 Figure 10 Parameters page 3 Operating Manual © Dürr Systems AG ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx Rev.02 – 03.07.2020...
  • Page 43 LEADING IN PRODUCTION EFFICIENCY Figure 11 Parameters page 4 Figure 12 Parameters page 5 Operating Manual © Dürr Systems AG ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx Rev.02 – 03.07.2020...
  • Page 44 LEADING IN PRODUCTION EFFICIENCY 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 ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx Rev.02 – 03.07.2020...

  • Page 45: Pre-Purge And Purge Cycle Page

    LEADING IN PRODUCTION EFFICIENCY 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 ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx Rev.02 – 03.07.2020...

  • Page 46: Alarm History Page

    LEADING IN PRODUCTION EFFICIENCY 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 ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx Rev.02 – 03.07.2020...

  • Page 47: External Control Interface Signal Page

    LEADING IN PRODUCTION EFFICIENCY 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 ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx Rev.02 – 03.07.2020...

  • Page 48: User Management Page

    LEADING IN PRODUCTION EFFICIENCY 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 ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx Rev.02 – 03.07.2020...

  • Page 49: Settings Page

    LEADING IN PRODUCTION EFFICIENCY 8.4.12 Settings page Figure 23 IP settings page Operating Manual © Dürr Systems AG ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx Rev.02 – 03.07.2020...

  • Page 50: Description And Operation Of Each Visualization Window

    LEADING IN PRODUCTION EFFICIENCY 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.
  • Page 51 LEADING IN PRODUCTION EFFICIENCY 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 52 LEADING IN PRODUCTION EFFICIENCY 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 53 LEADING IN PRODUCTION EFFICIENCY 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 54 LEADING IN PRODUCTION EFFICIENCY 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 55 LEADING IN PRODUCTION EFFICIENCY 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. Recipe data (Recipe table) and Calibration data (Calibration table) Consumption data Configuration data (Station configuration)
  • Page 56 LEADING IN PRODUCTION EFFICIENCY 8.5.1.6 USB Data Save/Load Operations 1) Insert USB stick in the IF4 – USB port. 2) Log-in with appropriate user level 3) Select the action that you want to perform 4) Push this button to execute the action 5) A message will be displayed with the result of the operation: The message disappears automatically after five seconds.
  • Page 57 LEADING IN PRODUCTION EFFICIENCY On the USB Stick are created: “EcoDose3K_ConfigData\Configuration” after saving Configuration to USB device, “EcoDose3K_ParamData\Parameters” after saving Parameters to USB device, “EcoDose3K_PurgeData\PurgePrograms” after saving Purge Programs to USB device, “EcoDose3K_RecipeData\Recipes” after saving Recipes to USB device, “EcoDose3K_Consumptions\Consumptions.csv” after saving Consumption to USB device, “E EcoDose3K_Weardata\Wearcounters”...
  • Page 58 LEADING IN PRODUCTION EFFICIENCY 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” field. After the new password has been entered in the appropriate field, change can be activated by the confirmation button.
  • Page 59 LEADING IN PRODUCTION EFFICIENCY 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 60 LEADING IN PRODUCTION EFFICIENCY 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. Tapping the “IP”...
  • Page 61 LEADING IN PRODUCTION EFFICIENCY 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 62 LEADING IN PRODUCTION EFFICIENCY 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.
  • Page 63 LEADING IN PRODUCTION EFFICIENCY In the right bottom of the screen there are three other buttons: copy, paste and save. Copy button using this button you can copy temporarily a row of the table Paste button using this button you can replace a previously row line with another Save button using this button you can save all the changes Tap on the row of the recipe whose calibration value you want to change.

  • Page 64: Cycle Programs - Recipe Selection

    LEADING IN PRODUCTION EFFICIENCY 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”, “calibration B”...
  • Page 65 LEADING IN PRODUCTION EFFICIENCY 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 greencolor, to show the progress of the cycle.
  • Page 66 LEADING IN PRODUCTION EFFICIENCY 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: to fill just the house portion involved in the calibration with one product, can be color or component B or C;...
  • Page 67 LEADING IN PRODUCTION EFFICIENCY 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 when cycle program Purged “Purge” is completed without error. Loading cycle program “Load”...

  • Page 68: Spray - Valves

    LEADING IN PRODUCTION EFFICIENCY 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 B channel valve of the recipe in use number of the C channel valve of the recipe in use...
  • Page 69 LEADING IN PRODUCTION EFFICIENCY Valves color valve solvent valve for color YPL1 purge air valve channel B valve YV1B solvent valve for channel B channel C valve BZL1 atomizing air pressure gun 1 BZL2 atomizing air pressure gun 2 YG 1 selection valve gun 1 YG 2 selection valve gun 2...
  • Page 70 LEADING IN PRODUCTION EFFICIENCY 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 71: Spray Data

    LEADING IN PRODUCTION EFFICIENCY 8.5.4 Spray data Figure 40 Spray data 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 ( channel) in ml/min the current flow in channel C (channel ) the current flow of mixed material in ml/min the dispensed quantity of A, B and mixed A+B and A+B+C in liter.

  • Page 72: Recipes Data

    LEADING IN PRODUCTION EFFICIENCY 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 Channel B valve number Channel C valve number...

  • Page 73: Pre-Purge, Purge Program

    LEADING IN PRODUCTION EFFICIENCY 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 74 LEADING IN PRODUCTION EFFICIENCY 8.5.6.1 Pre-purge purging sequence: sequence order of A, B or C T-V1 solvent time in seconds T-PL1 air time in seconds quantity of color solvent (channel A) in milliliter quantity of solvent channel B in milliliter quantity of solvent channel C in milliliter Phase 1: YV1 valve is opened for T-V1 seconds, then YPL1 valve is opened for T-PL1 seconds;...

  • Page 75: Consumption

    LEADING IN PRODUCTION EFFICIENCY 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 76: Parameters

    LEADING IN PRODUCTION EFFICIENCY 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 user: user...
  • Page 77 Atomization air valve is closed too, with the delay here specified. Default OFF [s] value 4 [s] If the EcoDose 3K supplies an automatic machine, set this option as YES. In this case automatic POT LIFE purge is allowed without checking signals from AUTOMATIC gun-flushing box;...
  • Page 78 LEADING IN PRODUCTION EFFICIENCY Figure 45 Parameters page 2 AUTOMATIC PURGE If the system is equipped with EcoCleaner M device, with the option Yes the Yes/No pot life alarm activates an automatic purge cycle While spraying loading or purging, the flow of the medium is controlled. When MINIMUM FLOW A the measured flow in channel A is consistently less than the quantity here [ml/min]...
  • Page 79 LEADING IN PRODUCTION EFFICIENCY To access this parameter, the option AUTOMATIC MACHINE must be set to No, it means the system is not used to supply an automatic machine. While spraying, if the flow of A or B falls consistently below the minimum set DELAY FINAL STOP limit MINIMUM FLOW A or B or C, after the time DELAY ALARM NO FLOW, ALARM [s]...
  • Page 80 LEADING IN PRODUCTION EFFICIENCY Figure 47 Parameters page 4 In order to keep YF color valve always open during the component B injection, DELAY VALVE YF (A) it can be kept opened for a short time here specified, even when there is a OFF [ms] surplus of color in the A/B mixing ratio.
  • Page 81 LEADING IN PRODUCTION EFFICIENCY Pressure or Closed loop. Pressure standard value: a consistent value of pressure, assigned by the operator, is applied to the flow regulator. FLOW CONTROL On system with one spray gun, equipped with a flow modulating valve, can be activated, when available, a closed loop flow control: assigned a flow set point value, while spraying, the control pressure of the regulator is automatically adjusted, to control the flow.
  • Page 82 LEADING IN PRODUCTION EFFICIENCY Figure 48 Parameters page 5 Only for system equipped with Coriolis flowmeter TEMPERATURE While spraying the temperature of color and component B and C are ALARM controlled. If the values of the temperature are consistently out of the intervals THRESHOLDS [C°], here specified, after the time specified in DELAY ALARM TEMPERATURE, DELAY ALARM...
  • Page 83 LEADING IN PRODUCTION EFFICIENCY 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. A warning message shows when the operations counter value has reached the limit and the component should be revised or replaced.

  • Page 84: Alarms Windows

    LEADING IN PRODUCTION EFFICIENCY 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...
  • Page 85 LEADING IN PRODUCTION EFFICIENCY 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 86: Messages And Alarm Groups

    LEADING IN PRODUCTION EFFICIENCY 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 Component C is not flowing Leakage valve channel A...
  • Page 87 LEADING IN PRODUCTION EFFICIENCY External recipe the recipe number from the external controller is null or beyond the maximum out of range 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 88 LEADING IN PRODUCTION EFFICIENCY Possible cause: the plant was switched off while it was not purged. Fault elimination: if the station was switched off with the red push button, press Plant switched off the green button to switch it on again, reset the alarm, run a purge cycle if you and not purged want to turn the plant off immediately after.
  • Page 89 LEADING IN PRODUCTION EFFICIENCY Analog Input Possible cause: wrong analog signal of temperature from PLC analog input Temperature B card Fault elimination: it requires maintenance intervention to check the electrical (C) only with Coriolis flowmeter connections Temperature B Possible cause: while spraying the temperature of the fluid component in (C) out of range channel B ( C ) is beyond the assigned limits in parameters TEMPERATURE only with Coriolis...
  • Page 90 LEADING IN PRODUCTION EFFICIENCY Group 3: Hardware alarms Alarm number Alarm Festo valve module CTEU-CO not OK Card X20AI2322 not OK Card X20AO4622 not OK Card X20AI4322 not OK Card X20PS2100 not OK Card X20DO8322 not OK Card X20BT9100 not OK Profibus Eco PUC not OK No heart beat from external control Wrong serial number.
  • Page 91 LEADING IN PRODUCTION EFFICIENCY Error in program initialization routine Error in recipes Possible cause: when powered, the PLC loads all the working data: cycle initialization routine program, recipes, configuration, parameters and consumption from files in the memory storage area. If the operation is unsuccessful this alarm is set. Error in configuration initialization routine Fault elimination: try to restore the missing data from a previous backup...
  • Page 92 LEADING IN PRODUCTION EFFICIENCY Possible cause: missing signal from booth external ventilation system control. Booth ventilation off Fault elimination: if the condition is inconsistent, check the external wiring connection. Tap on the reset alarm button on the panel. Possible cause: the emergency push button on the control panel is pressed. Emergency push Fault elimination: release the emergency button and tap on the reset alarm button triggered...
  • Page 93 LEADING IN PRODUCTION EFFICIENCY Group 5: Warnings Alarm number Alarm YF1 valve has been activated too many times, provide for maintenance YF2 valve has been activated too many times, provide for maintenance YF3 valve has been activated too many times, provide for maintenance YF4 valve has been activated too many times, provide for maintenance YF5 valve has been activated too many times, provide for maintenance YF6 valve has been activated too many times, provide for maintenance...
  • Page 94 LEADING IN PRODUCTION EFFICIENCY Wrong calibration data in required recipe Wrong purge program in required recipe YRF1 valve has been activated too many times, provide for maintenance YRF2 valve has been activated too many times, provide for maintenance YHN1 valve has been activated too many times, provide for maintenance YHN2 valve has been activated too many times, provide for maintenance Operating Manual ©...

  • Page 95: External Recipe Mode

    LEADING IN PRODUCTION EFFICIENCY 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”.

  • Page 96: External Control Interface

    LEADING IN PRODUCTION EFFICIENCY 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 AckTelCounter iTelCount on the remote controller iAlarmGrpIfoGlb1 Alarm group information byte 0/1 (global alarm) iAlarmGrpIfoGlb2 Alarm group information byte 2/3 (global alarm) Alarm group information byte 0/1 (application specific...
  • Page 97 LEADING IN PRODUCTION EFFICIENCY 44.1 iValveSate1_09 BOOL Color 10 Valve On 44.2 iValveSate1_10 BOOL YB1 Valve On 44.3 iValveSate1_11 BOOL YB2 Valve On 44.4 iValveSate1_12 BOOL YB3 Valve On 44.5 iValveSate1_13 BOOL YV1 Valve On 44.6 iValveSate1_14 BOOL YV1B Valve On 44.7 iValveSate1_15 BOOL...
  • Page 98 LEADING IN PRODUCTION EFFICIENCY 63.2 mG1inPos BOOL Gun 1 in EcoGun Cleaner M 63.3 mG2inPos BOOL Gun 2 in EcoGun Cleaner M 63.4 mStartAck BOOL Acknowledge signal stat consumption 63.5 mPotLifeAlarm BOOL System in pot life alarm 63.6 mPotLifePrealarm BOOL System in pot life pre-alarm 63.7 mSpare_63_7...

  • Page 99: Input From External Control Interface

    LEADING IN PRODUCTION EFFICIENCY 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 100 LEADING IN PRODUCTION EFFICIENCY 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 mStartLongPurge BOOL Start Long Purge 62.3 mStrobeNewRecipe BOOL Strobe for request new recipe 62.4 mMainNeedleG1Active BOOL Main needle Gun 1 active 62.5...

  • Page 101: External Interface Flowchart

    LEADING IN PRODUCTION EFFICIENCY 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 Operating Manual © Dürr Systems AG ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx Rev.02 –...
  • Page 102 LEADING IN PRODUCTION EFFICIENCY Example: consumption measure Example: life signal of telegram counter Example: abort active cycle program Example: set date and time Operating Manual © Dürr Systems AG ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx Rev.02 – 03.07.2020...

  • Page 103: Udp Connection Ecodose And External Control

    LEADING IN PRODUCTION EFFICIENCY 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 104: Closed Loop Flow Regulation

    LEADING IN PRODUCTION EFFICIENCY 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 ”Closed loop”. Figure 55 In this condition, assigned a flow set point value, while spraying, the control pressure of the regulator is consistently automatically adjusted, to control the flow.

  • Page 105: Regulator Page

    LEADING IN PRODUCTION EFFICIENCY 8.11.1 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 106 LEADING IN PRODUCTION EFFICIENCY 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.

  • Page 107: Regulation Table Data

    LEADING IN PRODUCTION EFFICIENCY 8.11.2 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 108 LEADING IN PRODUCTION EFFICIENCY 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 ∆...

  • Page 109: Graphic Representation

    LEADING IN PRODUCTION EFFICIENCY 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 110: Regulation Parameters

    LEADING IN PRODUCTION EFFICIENCY 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. 8.11.4 Regulation parameters In the regulation page, press the button to open the page of the regulation...
  • Page 111 LEADING IN PRODUCTION EFFICIENCY If air is sprayed with the gun, use this parameter to avoid the regulator output rises while the gun trigger is released. The regulator output gets frozen as soon as the measured flow falls below this limit. Rise the value of this parameter in order to get a prompt reaction of the Flow trigger off regulation: releasing the trigger the regulator output gets quickly frozen.

  • Page 112: External Interface Signal

    LEADING IN PRODUCTION EFFICIENCY 8.11.5 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 Colour flow. If the value of Set colour flow is zero, the flow set point value is taken from the actual recipe in use.

  • Page 113: Remote Magnetic Switch Panel

    LEADING IN PRODUCTION EFFICIENCY 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.

  • Page 114: Recipe Change + / - And Confirm

    LEADING IN PRODUCTION EFFICIENCY 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 115: Maintenance

    Always wear the following equipment during assembly operations. W A R N I N G Before performing any maintenance, on EcoDose 3K, the operator must ensure that: the power is shut down air and product supplies are intercepted all circuits (product / solvent / air) are...

  • Page 116: Control Panel

    In particular, check the correct tightening of terminal screws image indicative The EcoDose 3K PLC usually does not need any maintenance. The EcoDose 3K PLC is provided by a flash memory and does not need the installation of a buffer battery. Operating Manual ©...

  • Page 117: Fluidic Panel

    LEADING IN PRODUCTION EFFICIENCY 9.2 Fluidic panel Complete “fluidic panel” Coriolis version Gear version Daily inspect fluidic panel for visible damage. C.C. Valves EcoMCC 200 EcoValve7 20 EcoMCC3 C.c valves should be inspected periodically following the manufacturer's instructions (attached to this manual).
  • Page 118 LEADING IN PRODUCTION EFFICIENCY “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. For disassembly, follow the manufacturer's instructions (see Chapter 11 documents) The accuracy of the measuring cell must be checked at regular...
  • Page 119 LEADING IN PRODUCTION EFFICIENCY EXCLUSION “GEAR FILTER” (only for versions with gear Flowmeter) If there should be the need of removing one or both “GEAR FILTER” from the mixing panel due to the particular kind of paint and/or catalyst used, proceed as follows: A Remove the “GEAR FILTER”...

  • Page 120: Parts List

    See the drawings attached 10.1 Drawings drawing n. rev. description EcoDose 3K general assembly - GEAR flowmeter version LP 0300040.CM.GE.01 EcoDose 3K general assembly - GEAR flowmeter version HP 0300040.CM.GE.02 0300040.CM.GE.03 EcoDose 3K general assembly - CORIOLIS flowmeter version LP 0300040.CM.GE.04...

  • Page 121: Attached Documents

    LEADING IN PRODUCTION EFFICIENCY 11 Attached documents Documentation of vital components Supplier Description Model Code Endress + Hauser Coriolis flow meter Promass 80 W07020175 Gear flow meter 0,005-2 l/min. ZHM 01/1 W07020134 Gear flow meter 0,02-3 l/min. ZHM 01/2 W07020133 Low Pressure Regulator Flow EcoFlow LPF P 7 N26010101...

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