Concept 4 - 8 - 12 - 18 v3.04 EN Manuaal PDF
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Description
Operating Manual Hotmelt Applicators Concept 4, 8, 12, 18 Part No. 112532 / Edition 4.1 Program ICS-MAIN from version 3.04
Publisher:
Robatech AG Pilatusring 10 CH-5630 Muri Switzerland Phone Fax Email Internet
+41 (0)56 675 77 00 +41 (0)56 675 77 01 info @ robatech.ch www.robatech.com
Date of issue: May 2002 © Copyright by Robatech AG All rights reserved. Without Robatech's written approval it is not permitted to copy and distribute this manual or parts thereof in any form whatsoever, or to transmit it by means of electronic systems. The illustrations and information contained in this Operating Manual are subject to technical alterations necessary for the enhancement of the appliance.
Table of contents 1
Product description __________________________________________________________ ______ 5
1.1
Use for the intended purpose ................................................................................................................. 5
1.2
Improper use.............................................................................. ............................................................ 5
1.3
The operating manual ............................................................................................................................ 6 1.3.1 How to use this manual............................................................................................................ . 6 1.3.2 Program modifications ICS-MAIN ........................................................................................... 7
1.4
1.3.3 Content and topicality ............................................................................................................... 7 Appliance identification......................................................................................................................... 7
1.5
Overview of the appliance ..................................................................................................................... 8
1.6
Technical data ....................................................................................................................................... 9
1.7
Conformity Conformity,, standards complied with................................................................................................... 10
2
Safety _______ ______________ ______________ _____________ _____________ ______________ _____________ _____________ ______________ ______________ _____________ ______ 11
2.1
References contained in the operating manual ..................................................................................... 11
2.2
Dangers of handling/operating the appliance ....................................................................................... 11 2.2.1 Danger of burns ...................................................................................................................... 11 2.2.2 Danger of splashing ................................................................................................................ 12 2.2.3 Electrocution .......................................................................................................................... 12 2.2.4 Irritations of the mucous membranes ...................................................................................... 12
2.3
General safety prescriptions................................................................................................................. 13
2.4
Safety features ..................................................................................................................................... 13
2.5
Qualified personnel.............................................................................................................................. 13
2.6
Personal protective equipment............... .............................................................................................. 14
2.7
Procedure in case of an emergency................................. ..................................................................... 14 2.7.1 Skin burns......................................................................................................................... ...... 14 2.7.2 Electrical accident .................................................................................................................. 14 2.7.3 Extinguishing hotmelt applicators on fire................................................................................ fire................................................................................ 15
3
Transport and scope of supply ______________________________________________________ 17
3.1
Packaging ............................................................................................................................................ 17
3.2
Transport ............................................................................................................................................. 17
3.3
Scope of supply ................................................................................................................................... 17
4
Appliance overview and functions ___________________________________________________ 18
4.1
Overview of the appliance ................................................................................................................... 18
4.2
Functioning of the appliance................................................................................................................ 18
4.3
Tank with distributor ........................................................................................................................... 19
4.4
Piston pump........................................................ ................................................................................. 19
4.5
Operating unit............................................................................................................................. ......... 20
4.6
Control electronics............................................................................................................................... 21 4.6.1 Standard..................................................................................................................................21 4.6.2 Options ................................................................................................................................... 21 4.6.3 Wiring diagram....................................................................................................................... 22 4.6.4 Specifications of the ICS-MAIN main control ........................................................................ 23
5
Installation and first commissioning _________________________________________________ 25
5.1
Place of positioning ............................................................................................................................. 25
Concept / 4.1
Table of contents
1
5.2
Installing the heated hoses ................................................................................................................... 27 5.2.1 Installation examples .............................................................................................................. 28 5.2.2 Electrical connection .............................................................................................................. 30
5.3
Pneumatic connection .......................................................................................................................... 30
5.4
Electrical connection ........................................................................................................................... 31 5.4.1 Checks prior to connection ..................................................................................................... 31
5.5
Higher-rankin Higher-ranking g system controls ........................................................................................................... 32 5.5.1 Data ........................................................................................................................................ 32 5.5.2 5.5.3 5.5.4 5.5.5
Signals .................................................................................................................................... 32 Connection of PLC control ..................................................................................................... 34 Connection of relay control..................................................................................................... 35 Wiring in compliance with EMC............................................................................................. 36
5.6
Installation of accessories and options ................................................................................................. 36
5.7
First commissioning............................................................................................................................. commissioning............................................................................................................................. 37
6
Operation _________________________________________________________ ______________ 39
6.1
Filling in hotmelt ................................................................................................................................. 39
6.2
Switching on and off......................................................................... ................................................... 39
6.3
Setting the feed quantity / glue pressure............................................................................................... 40
6.4
Draining the system pressure ............................................................................................................... 40
6.5
Operating concept................................................................................................................................ 41 6.5.1 Overview of the appliance functions ....................................................................................... 41
6.6
Appliance status................................................................................................................................... 42 6.6.1 Overall status .......................................................................................................................... 42 6.6.2 Heating zone status ................................................................................................................. 43 6.6.3 Heating zone and system errors............................................................................................... 43
6.7
Access blockage .................................................................................................................................. 44
6.8
Setting and checking the temperatures ................................................................................................. 44 6.8.1 Displaying temperatures ......................................................................................................... 44 6.8.2 Capturing the temperatures ..................................................................................................... 45 6.8.3 Checking the heating output.................................................................................................... 45
6.9
Entering parameters............................................................................................................................. parameters ............................................................................................................................. 46 6.9.1 Before you alter parameters .................................................................................................... 46 6.9.2 Capturing the parameters ........................................................................................................ 47 6.9.3 Saving the program settings .................................................................................................... 48 6.9.4 Loading the program settings.......... ........................................................................................ 48 6.9.5 6.9.6 6.9.7 6.9.8 6.9.9 6.9.10 6.9.11 6.9.12 6.9.13 6.9.14 6.9.15 6.9.16 6.9.17 6.9.18
2
Putting back the program to the default setting ....................................................................... 48 Parameter 1…18: Compensation factors ................................................................................. 49 Parameter 20: Temperature differential tank - heated hoses .................................................... 49 Parameter 21: Temperature differential tank- application heads.............................................. 49 Parameter 22: Heating-up order .............................................................................................. 49 Parameter 23: Temperature - unit of measuremen measurementt .................................................................. 50 Parameter 24: Sta Standstill ndstill supe supervision, rvision, time until temperature lowering .................................... 50 Parameter 25: Standstill supervision, time until switch-off ..................................................... 50 Parameter 26: Activating the input H-ENABLE......................................................................50 Parameter 27: Configuration of input P-ENABLE1 ................................................................ 50 Parameter 28: N Number umber of heated hoses / applica application tion h heads eads ..................................................... 51 Parameter 29: Configuration of tank heating 2 (Premelter) ..................................................... 51 Parameter 30: Maximum nominal temperature........................................................................ 51 Parameter 31: Waiting time after reachin reaching g of the tank nominal temp. ..................................... 51
Table of contents contents
Concept / 4.1
6.9.19 6.9.20 6.9.21 6.9.22 6.9.23 6.9.24 6.9.25 6.9.26
Parameter 32: C Configuration onfiguration of aaccess ccess blockage PAR-LOCKED PAR-LOCKED2.......................................... 2.......................................... 51 Parameter 33: Melting time activating temperature................................................................. 52 Parameter 70: R Resetting esetting of the service messages A90…A92...................................................52 Parameter 71: Operating hours until «Check filter» ................................................................ 52 Parameter 72: Operatin Operating g hou hours rs until «Clean complete system................................................. 52 Parameter 73: Operatin Operating g hou hours rs until «Free service message».................................................. message».................................................. 52 Parameter 80: Temperature inside the appliance ..................................................................... 53 Parameter 81: Standstill time .................................................................................................. 53
6.9.27 6.9.28 6.9.29 6.9.30
Parameter 82: Battery voltage............................................................................ ..................... 53 Parameter 90: Applied program .............................................................................................. 53 Parameter 91: Program version ............................................................................................... 53 Parameter 200: Existence of extra board ICS-EXT1 ............................................................... 53
6.10
Querying and setting the clock time ..................................................................................................... 54
6.11
Time switch clock................................................................................................................................ 55
6.12
Temperature lowering.......................................................................................................................... 56 6.12.1 Determination of the lowered temperatures............................................................................. 56 6.12.2 Manual switching-on of temperature lowering ........................................................................ 56
7
Maintenance Maintenance _______ _____________ _____________ ______________ ______________ _____________ _____________ ______________ _____________ _____________ ________ _ 57
7.1
References ........................................................................................................................................... 57
7.2
Maintenance schedule.......................................................................................................................... 58
7.3
Flushing of the filter ............................................................................................................................ 59
7.4 7.5
Replacing the filter .............................................................................................................................. 59 Cleaning of the appliance..................................................................................................................... 60 7.5.1 Cleaning agent ........................................................................................................................ 60 7.5.2 Complete cleaning .................................................................................................................. 61
8
Repair______ ____________________________________________________ ________________ 63
8.1
References ........................................................................................................................................... 63
8.2
Replacing heated hoses and application heads ..................................................................................... 64
8.3
Repairing the piston pump ................................................................................................................... 65 8.3.1 Irregularities on pumping........................................................................................................ 65 8.3.2 Removal and installation of the piston pump .......................................................................... 66
8.4
Replacing temperature sensors............................................................................................................. 67
8.5
Resetting the temperature limiter ......................................................................................................... 67
8.6
Checking the electrical connections ..................................................................................................... 68 8.6.1 8.6.2
Checking the heated hose connection...................................................................................... 68 Checking the piston pump connection..................................................................................... 69
8.7
Connection assignment of boards ICS.................................................................................................. 69 8.7.1 ICS-MAIN Main control......................................................................................................... 70 8.7.2 ICS-PWR1 Tank heating ........................................................................................................ 73 8.7.3 ICS-PWR2 Heating of heated hoses and application heads heads..................................................... ..................................................... 74 8.7.4 ICS-PUS Piston pump control................................................................................................. 75 8.7.5 ICS-PWRD1 Power distribution ............................................................................................. 76 8.7.6 ICS-PWRD3 Power distribution ............................................................................................. 77
8.8
Pump disturbances disturbances............................................................................................................................... ............................................................................................................................... 78
8.9
Disturbances in the hotmelt application ............................................................................................... 79
9
Putting out of operation operation and dispo disposal sal _____________ ___________________ _____________ _____________ _____________ _____________ _________ ___ 83
9.1
Putting out of operation ....................................................................................................................... 83
9.2
Disposal...............................................................................................................................................83
Concept / 4.1
Table of contents
3
10
Spare parts_____________ _________________________________________________________ 85
10.1
Introduction ......................................................................................................................................... 85
10.2
Hand tools and auxiliary materials....................................................................................................... 85
10.3
Exchange components ......................................................................................................................... 86
10.4
Basic appliance.................................................................................................................................... 86
10.5
Electrical parts................................................................... .................................................................. 87
10.6
Piston pump KPC12 ............................................................................................................................ 88 10.6.1 Spare parts .............................................................................................................................. 88
10.7
10.6.2 Set of seals KPC12 ................................................................................................................. 88 Piston pump KPC5 .............................................................................................................................. 89 10.7.1 Spare parts .............................................................................................................................. 89 10.7.2 Set of seals KPC5 ................................................................................................................... 89
10.8
Piston pump KPC16 ............................................................................................................................ 90 10.8.1 Spare parts .............................................................................................................................. 90 10.8.2 Set of seals KPC16 ................................................................................................................. 90
11
Accessories _______________________________________________________________ _______ 91
11.1
Heated hoses and accessories............................................................................................................... 91 11.1.1 Standard heated hoses, nominal width 8mm............................................................................ 91 11.1.2 Screw fittings.................................................................................................................... ...... 91 11.1.3 Extension cables ..................................................................................................................... 92 11.1.4 Distribution cables cables.................................................................................................................. .................................................................................................................. 93
11.2
11.1.5 Accessories for heated hoses................................................................................................... 93 Controls and accessories........................................................ .............................................................. 94 11.2.1 Photoelectric cells and proximity switches.............................................................................. 95 11.2.2 Valve cables ........................................................................................................................... 96 11.2.3 Power supplies ICS-PSUP ...................................................................................................... 96 11.2.4 Encoder .................................................................................................................................. 97 11.2.5 Proportional valves and accessories accessories........................................................................................ ........................................................................................ 98
11.3
Pumps..................................................................................................................................................99
11.4
Level sensors ....................................................................................................................................... 99
11.5
Pressure relief kit........................................................................................................................ ......... 99
11.6
Maximum pressure valve ................................................................................................................... 100
11.7
Installation kits for operating unit ICS-TRM ..................................................................................... 100
11.8
Various accessories............................................................................................................................ 101
11.9
Plugs, cable sockets and cables.......................................................................................................... 101
11.10 Operating instructions........................................................................................................................ 102 12
Appen Appendix dix _______ ______________ _____________ _____________ ______________ ______________ ______________ _____________ _____________ ______________ _________ __ 103
12.1
Power distribution and admissible loading......................................................................................... 103 12.1.1 Supply 400 V VAC AC 50Hz 3-phase with neutral conductor ........................................................ 103 12.1.2 Supply 230 VAC 50Hz 1-phase ............................................................................................ 104
12.2
Quick reference ................................................................................................................................. 105
13
Key word index _______ ______________ _____________ _____________ ______________ _____________ _____________ ______________ _____________ ___________ _____ 107
4
Table of contents contents
Concept / 4.1
1
Product description
1.1
Use for the intended purpose
The Concept units units are hotmelt applicators and serve to melt, feed and apply thermoplastic hotmelts in an industrial environment. They are hotmelt application systems of a modular structure. Subject to the pertaining technical data (see chapter 1.6) they are intended for the following applications: The Concept applicators are intended for melting down and feeding thermoplastic hotmelts on the basis of EVA (Ethylene-vinylacetate). The application range reaches from dry (packaging) to sticky (labelling, adhesive hotmelt).
Robatech's specific approval must be obtained in any case if polyamide or polyethylen are to be processed. Unless Robatech's written approval concerning the processing proces sing of special hotmelts has been obtaine obtained d beforehand, no liability will be accepted in case of a damage to the system.
1.2
Improper use
Below are some examples, without limitation, of activities by the owner or operator of the appliance which are considered to be improper use: –
Any other use than that for the intended use, without the manufacturer's written approval, or any operation outside the technical limits are deemed to be improper.
–
The Concept units units are specifically not suitable for the processing of polyurethane hotmelts. This material would crosslink inside the system after a few hours, form clots and solidify irreversibly.
–
Adhesives containing solvents must not be used. A danger of fire and explosion exists on heating of such materials.
–
It is strictly prohibited to modify the appliance in any way without without the prior written approval of Robatech.
–
Operation of the appliance by unqualified personnel is prohibited.
–
Failure to observe the safety and operating instructions and to comply with work protection, accident prevention as well as particular local regulations is deemed to be improper practice.
Concept / 4.1
Product description
5
1.3
The operating manual
The information contained in this operating manual refers to:
All «Concept» hotmelt applicators of Robatech from program version 3.04 with piston pump Without integrated pattern control ICS-IK4x and without gear pump
The operation of the pattern control ICS-IK and of the gear pump ZPC is not described in this manual. Dedicated manuals are available for these options (see chapter 11.10). Neither is the operation of the application heads described in this manual. A dedicated manual is available for each type of application head. This manual can be obtained in the languages English, German, French, Italian and Spanish; other languages on request from the respective local representative. The operating manual is a part of the appliance. Keep it ready for immediate use so that any item can be looked up quickly whenever necessary. The manual must be understood and complied with in every respect by all those persons who are responsible for transport, installation, operation, maintenance and repair of the appliance.
1.3.1
How to use this manual
Chapters 1 to 4 provide the necessary basic knowledge which every user must acquire for his/her work with the «Concept» appliance. Chapter 6 includes information describing the operation of the appliance in the normal case, i.e. in troublefree running. Chapters 5 and 7 to 11 include jobs which deviate from normal operation, i.e. maintenance, commissioning, the elimination of disturbances or the ordering of spare parts.
At the end of the manual you will find information which facilitates the use of the operating manual, e.g. a key word index and additional technical information.
Please read the manual carefully. Take particular note of chapter 2 «Safety» – so that you can operate the appliance safely and without accidents.
6
Product description description
Concept / 4.1
1.3.2
Program modifications ICS-MAIN
Program ICS-MAIN from version 3.00 to 3.04: – New operation operat ion sta status tus A90, A91 and A9 A92 2 for sservice ervice messages – New parameters paramete rs 70, 71, 72 and 73 for re resetting setting and a nd sett setting ing of the service messages – Parameter 32: Extended blockage of «Loc1» or «Loc1+2» – Resetting of the standstill supervision in parameters 24 and 25 via key – Saving of all data (also glue patterns) via «2222» whe when n switching on Program ICS-MAIN from version 2.06 to 3.00: – Support of the new ICS-MAIN board with modified layout. New inputs and outputs. – Parameter 32 with new configuration
1.3.3
Content and topicality
This manual is complete and current , if it contains the following pages: Documentation
Content
Edition
Operating manual, basic unit
page 1 … 110
4.1
Table of parameters, basic unit
page I … II
from program 3.04
Wiring diagram
page 1 … 9
of 03.05.02
1.4
Appliance identification
The type label is on the rear side of the appliance.
Concept / 4.1
Typ
Appliance version with installed options
Baujahr
Year of manufacture [Year – week – serial number]
Art.Nr.
Article number
Volt
Electrical connection values
Ampère
Maximum current consumption per phase
Product description
7
1.5
Overview of the appliance
The Concept appliances are of a modular design and available in different executions and with various options. The overview below shows the subassemblies of the standard executions. A. – – – –
Basic appliances Concept 4 with a tank volume of 4 litres Concept 8 with a tank volume of 8 litres Concept 12 with a tank volume of 12 litres Concept 18 with a tank volume of 18 litres
B. – – –
Controls Temperature control (standard) Integrated pattern control ICS-IK4x Gear pump control ICS-PINT
C. Feed pumps – Piston pump KPC12 (standard) – Piston pump KPC5 – Piston pump KPC16 – Gear pump ZPC2.3 (standard) – Gear pump ZPC 2.75 – –
Gear pump ZPC 1.5 Gear pump ZPC 0.3
D. – – – –
Connections for hoses and heads 2 heated hoses and 2 application heads 4 heated hoses and 4 application heads 6 heated hoses and 6 application heads 8 heated hoses and 8 application heads
The operation of the integrated pattern control ICS-IK and of the gear pump ZPC is not described in this manual. Dedicated manuals are available for these options.
8
Product description description
Concept / 4.1
1.6
Technical data Concept 4
Concept 8
Concept 12
Concept 18
4 litres
8 litres
12 litres
18 litres
Tank lid opening
130 × 115 mm
130 × 209 mm
205 × 209 mm
205 × 339 mm
Melting capacity
6 kg/h*
10 kg/h*
12 kg/h*
18 kg/h*
Tank content
Piston pump types Pumping rate KPC 12 / KPC 5 KPC 16
KPC12 (standard), KPC5 or KPC16 max. 50 kg/h max. 160 kg/h max. 72 bar max. 30 bar max. 96 bar
Output pressure KPC 12 KPC 5 KPC 16
100…20,000 mPa s
Viscosity Compressed air supply Air consumption
6 bar, not oiled, purified max. 27.5 l/min max. 11.4 l/min max. 111 l/min
KPC 12 KPC 5 KPC 16
Heated hoses and application heads
max. 4 each
Operating temperature
max. 6 each
according to Euronorm EN60204-1**
± 0.5° C 230 V, 1 LNPE 400 V, 3 LNPE
400 V, 3 LNPE
1.8 kW
3.0 kW
Weight (with KPC12)
400 V, 3 LNPE
3.0 kW
4.5 kW
0…45° C
Ambient temperature Dimensions L×W×H [mm]
400 V, 3 LNPE
50/60Hz
Mains frequency Power consumption Tank
max. 8 each
20…230° C / 68…446° F
Temp. feedback control accuracy Operating voltages
max. 8 each
545 × 310 × 601 601 34 kg
680 680 × 310 310 × 570 680 680 × 385 × 570 570 44 kg
54 kg
806 × 385 385 × 570 570 59 kg
< 70dB(A)
Sound pressure
* Guide value, melting capacity depends on the adhesive ** Admissible deviation from the permanent operating voltage: 0.9...1.1 of the rated voltage
Concept / 4.1
Product description
9
1.7
Conformity, standards complied with
The Concept appliances appliances satisfy all applicable basic safety and health requirements. The appliances have been developed, designed and manufactured in compliance with the listed EU directives. In case of a product modification without Robatech's approval this declaration becomes void.
10
–
Directive 98 / 37 / EC relating to machinery
–
Directive 89 / 336 / EEC relating to electromagne electromagnetic tic compatibility
–
Directive 72 / 23 / EEC relating to electrical equipment designed for use within certain voltage limits (low voltage equipment)
–
Euronorm EN 60204-1 Safety of machines - Electrical equipment of machines
Product description description
Concept / 4.1
2
Safety
The Concept appliances appliances can be operated easily and safely by the instructed user. Inadequately trained users, on the other hand, can cause material and personal damage by incorrect behaviour. This chapter informs you of the safety concept and the prerequisites which must be met for a safe and optimal utilization of the appliance. This chapter must be read by all persons authorized to commission, operate, maintain or repair the appliance.
2.1
References contained in the operating manual
The framed reference boxes in this manual will show you different reference symbols which warn of possible dangers and situations and which must be observed under all circumstances. Symbol
Signal word
Immediately threatening danger
Death or most serious injuries
Warning
Possibly dangerous situation
Possibly death or most serious injuries
Caution
Possibly dangerous situation
Minor injuries
—
Possibly harmful situation
Material damage to product or the environment environment
—
Tips for application or other No dangerous danger ous or harmful useful information situation
Danger
2.2 2.2.1
Consequences in case of non-observance
Meaning
Dangers of handling/operating the appliance Danger of burns
Warning
Danger of burns There is a danger of suffering burns from parts of the heated-up appliance which are not covered and in case of contact with the hotmelt (temperatures up to 230°C / 446°F). The heated-up unit must not be transported or moved. Failure to comply might result in hot adhesive coming out. Heat-resistant protective gloves must be worn for all adjustment or maintenance jobs on hot parts of the unit or in case of possible contacts with hotmelt. Parts of the unit remain hot for a longer period also after the unit has been switched off.
–
The hot areas on tank lid, feed pump and distributor block on the rear side of the appliance are marked with the warning sticker on the right.
Concept / 4.1
Safety
11 11
2.2.2
Danger of splashing
Warning
Danger of splashing The hot adhesive in the lines is under a high pressure. At the application heads or if the pressure system is opened there is a danger of hot splashes occurring. If the pressure system has to be opened, the entire appliance must be relieved of pressure beforehand (see chapter 6.4). Protective goggles must be worn under all circumstances for all adjustment or maintenance work on parts under pressure such as pump, distributor block, heated hose or application head.
A label on the rear side of the appliance warns of the high pressure loads and temperatures which may occur.
–
2.2.3
Electrocution
Danger
Electrocution Mortal danger exists on touching of live components (operating voltage 400Volt). The protective covers may only be removed if the power supply to the appliance is interrupted. Connection of the appliance to the power mains or other work on the power circuit may only be carried out by persons trained for the purpose, i.e. electricians or electrical fitters.
This sticker on the covers on the front and on both sides warns of unauthorized opening and draws attention to the correct procedure.
–
2.2.4
Irritations of the mucous membranes
Caution
Irritations of the mucous membranes by vapours Even if the prescribed processing temperatures are complied with, hotmelt adhesives can emit annoying smells and might lead to irritations of the mucous surfaces. The appliance may be operated in sufficiently aerated rooms only. Keep the tank lid closed! Do not exceed the recommended processing temperature ! The data sheet provided by the producer of the hotmelt must be observed.
12
Safety Safety
Concept / 4.1
2.3
General safety prescriptions
The following general safety prescriptions must be observed as well: –
The Concept appliance may only be operated, maintained and repaired by authorized and trained persons.
–
If it must be assumed that an operation without danger is no longer assured, the appliance must be put out of operation and protected against unintentional switching on.
–
In addition to the information contained in the operating manual, you must comply with legal requirements and the provisions on accident prevention and protection of the environment in your country.
–
Do not modify the appliance in any way without having received Robatech's written approval.
2.4
Safety features
The Concept appliances appliances are built to the current level of safety engineering and feature the following safety and protection devices in standard execution: –
Appliance Applianc e swi switch tch – interrupts the power supply to the control of the appliance
–
Automatic switc switching-o hing-off ff of all he heater aterss at an ambient temperature >65° C / 149° F
–
Automatic switc switching-o hing-off ff of all he heater aterss at a tank temperature >230° C / 446° F
–
Connection Conne ction for extern e xternal al emer emergenc gency-off, y-off, the feed pump can be stopped immediately
–
Monit oring of the program progr am ssequenc equencee – in case of error errorss all outputs are switched off within 250 ms and the program is restarted
2.5
Qualified personnel
The appliance may only be operated, serviced and repaired by authorized and trained personnel. Based on their physical disposition, training and experience, these persons are able to safely attend to operation, service and repair of the appliance. This qualified personnel must be familiar with the safety and accident prevention regulations and aware of the company-internal work instructions. The owner/operator of the appliance is responsible for the personnel's training. The level of knowledge can be ascertained and intensified with productspecific training by Robatech. Appliance operator The operator must be familiar with the appliance to the extent that he/she can run it including accessories and periphery periphe ry in trouble trouble-free -free product production. ion. Prere Prerequisite quisite for this is a good technical understanding understa nding and at least the reading and understanding of chapters 1, 2, 4 and 6 of this operating manual. Technician The technician must have a more extensive knowledge of the appliance. The person must have absolved a basic training in mechanics/electrics and acquired elementary knowledge of pneumatics and hydraulics to be able to put the machine in operation, to maintain and repair it. The person must read and understand the chapters 1-9 in this manual.
Concept / 4.1
Safety
13 13
2.6
Personal protective equipment
Working clothes covering arms and legs must be worn under all circumstances.
A pair of gloves and protective goggles must be worn under all circumstances for work on the hot and pressurized appliance components, in particular for putting into operation, maintenance and repairs. Danger of splashes and burns! Robatech offers suitable protective equipment for this purpose: Mainten purpose: Maintenance ance kkit it Art. Art.No.1006 No.100660 60 consisting of a pair of protective gloves, protective goggles and a nozzle cleaning kit of 6 parts.
2.7
Procedure in case of an emergency Please observe the information below. If an emergen emergency cy occurs contrary to expectations, the information below will help you to proceed correctly in keeping the damage within limits and in preventing possible further damage.
2.7.1
Skin burns
–
The extent of an injury from burning cannot be assessed immediately after the accident. The body must first react to the effects of the high temperature. Soft parts of the body injured by burns and going dead are particularly particul arly endangere endangered d by infection infections. s. Only small, superfi superficial cial burns may be treated by the patient, otherwise a doctor's attention is necessary!
–
In many cases burns will leave ugly scars which may interfere with movements. Burns in the face and on the hands must always be treated by the doctor.
–
Whenever possible, cool burns as quickly as possible under cold flowing, clean water. Then apply sterile material, e.g. sterile gauze compresses. Do not use wound powder or oil, ointment or similar. If no sterile bandage material mat erial iiss available, avail able, us usee fresh freshly ly ironed hankerchiefs or lin linens. ens. Do not open ope n or re remove move blisters. blis ters.
2.7.2
Electrical accident
–
Switch the power off immediately (e.g. switch to 0, pull out mains plug, remove fuse)
–
If you are affected personally, you must apply all your strength to come free of the power circuit (push yourself away, drop on the floor, pull out mains plug by walking away away,, etc.)
–
Don't forget to protect yourself in a rescue operation. Stand on an insulated spot, touch a person under electrical current with insulating dry objects only (clothes, wooden handle, etc.), tear or push the victim away from the power circuit.
–
Rest the injured person correctly. Give artificial respiration immediately if the person subject to the accident stops breathing. In case of a circulatory collapse, give artificial respiration and apply external heart massage immediately.
–
Call a doctor right away.
14
Safety Safety
Concept / 4.1
2.7.3 –
Extinguishing hotmelt applicators on fire
In case of a fire, use a CO 2 extinguisher or dust extinguisher. Every person working on the «Concept» hotmelt applicator must know the location of the next fire extinguisher.
Danger
Electrocution Hotmelt applicators on fire must not be extinguished with water, otherwise there is a mortal danger from electrocution. If no other medium but water is available, the power supply to the appliance must be disconnected before extinguishing.
Warning
Danger of burns On extinguishing the burning appliance with water there is an additional, increased danger of burns from hot water vapours and splashes of hotmelt. Make sure you observe the remarks on personal protection equipment in chapter 2.6.
Concept / 4.1
Safety
15 15
16
Safety Safety
Concept / 4.1
3
Transport and scope of supply
3.1
Packaging
The Concept appliances appliances are packed in a solid cardboard box:
Dimensions L×W×H [mm]
Concept 4
Concept 8
Concept 12
Concept 18
805 × 460 × 670
805 × 460 × 670
805 × 460 × 670
940 × 460 × 670
Weight min. 40 kg* min. 50 kg* min. 60 kg* * Weight of basic Concept appliance without accessories packed in same consignment consignment
min. 65 kg*
The handling symbols on the box must be observed: observe d:
Delicate Instruments Top
Protect from wet
Fragile
Sensitive appliance
Do not drop
Do not drop
Use only the original box for all transports.
3.2
Transport
Please observe the following points for transport: –
Transport the appliance carefully to prevent damage due to the application of force or careless loading and offloading.
–
Immediately after taking delivery, check the appliance for transport damage. Deficiencies must be reported to Robatech immediately immediately..
In case of transport after commissioning, watch the following points: –
The hotmelt applicator must not be packed or transported while it is still hot.
–
Components which convey hotmelt material can only be dismantled in heated-up condition. Make sure you observe chapters 8.2 and 8.3 in this context.
3.3
Scope of supply
–
The scope of supply must be checked against the positions on the delivery documents. The delivery papers are stuck to the top of the box.
–
Missing items must be reported to Robatech immediately.
Concept / 4.1
Transport and scope of supply
17
4 4.1
Appliance Appliance overview overview and functions Overview of the appliance
1. Appliance switch 2. Operating unit
14. 15.
Heated hose connection Heated hose
3. Control electronics 4. Power supply/electronic connection 5. Tank lid 6. Melting tank 7. Heating elements 8. Feed pump 9. Feed pump connection 10. Coarse filter 11. Distribution Distribution block with drain valve 12. Filter cartridge 13. Plug sockets for heated hoses
16. 17.
Plug for heated hose Plug socket for application head
Not described descri bed in this manual: man ual: 18. Application head 19. Heating part 20. Spray element 21. Nozzle 22. Valve 23. Plug for application head
4.2 Functioning of the appliance After switching-on of the appliance, the hotmelt material in the tank is melted and heated up to processing temperature. As soon as tank, heated hoses and application heads have reached their temperatures, the feed pump is released release d for producti p roduction, on, i.e i.e.. the pump can star startt feedin feeding g hotmelt. The liquid hotmelt is drawn through the coarse filter into the feed pump and pressurized. The hotmelt then flows through the fine filter to the heated hose connections and into the heated hoses which feature the application heads at their ends. The T he hotmelt is applied to the product by spraying or airspraying.
18
Appliance overview and functions functions
Concept / 4.1
4.3
Tank with distributor
1. 2. 3. 4. 5.
Tank Tank lid Heating elements Temperature sensor Temperature limiter
6. Distributor block 7. Heated hose connections 8. Filter cartridge 9. Drain valve screw 10. Drain opening
4.4
Piston pump
The standard piston pump for the «Concept» appliances is of type KPC12 illustrated below. Two further types, KPC5 and KPC16, are available to cover special requirements (see chapter 1.6, technical data). Design and operation, however, are the same for all three types.
1. 2. 3. 4. 5. 6.
Piston pump Fixation ring Sight gl glass ass to check check the stroke movement movement Control electronics Pressure gauge Pressure controller
7. Compressed air connection 8. Cylinder 9. Type label with designation 10. Power supply connecting cable
Concept / 4.1
Appliance overview and functions
19
4.5
Operating unit
Actual operation of the appliance is by means of the operating unit. The temperatures, operating stati, time switch clock and all appliance parameters are indicated/displayed and can be altered. All functions are described in detail in chapter 6.
1 Appliance switch
7
LCD display for the code of the appliance status, the parameter number or the current day of the week. Light indication for the selected function. Selection keys for altering the values.
8
Switching on and off of temperature lowering
9
Switching on and and off of the time switch clock
2 Light indications for the current operating status. 3 Light indications for the selected heating zone. 4 Selection keys ffor or the heating zone an and d heatin heating g zone number (if more than 1 heated hose/head). LCD display of the heating zone number. 5 Selection keys keys for the program functions and the operating parameters. Light indication of the
selected function. 6 LCD display showing the value of the function or parameter selected in field 5. Light indications for the units of measurement. Selection keys for altering the values.
20
10 Operating field reserved for the optional pattern control ICS-IK4x; see the corresponding
manual. 11 Operating ffield ield reserved for the gear pump pump control; see the corresponding manual.
Appliance overview and functions functions
Concept / 4.1
4.6
Control electronics
The electronic control (ICS) of the «Concept» appliances is located under the operating front panel and covered. It is of a modular design and depends on the execution of t he appliance.
4.6.1
Standard
Listed below are the electronic components of the standard version, i.e. without application control, gear pump control, cont rol, p premelter remelter heating and external operat operating ing unit: ICS-MAIN
Main control
ICS-TRM
Operating unit
ICS-PWR1
Power control of tank heating
ICS-PWR2/2
Power control for 2 heated hoses and application heads Power control for 4 heated hoses and application heads
ICS-PWR2/4
4.6.2
ICS-PWRD1
Single-phase power distribution (only Concept 4/2 with 230 Volt)
ICS-PWRD 3
3-phase power distribution 400 Volt
ICS-PSUP1
Power supply unit 24 Volt with 40, 60 or 100 Watt power
Options ICS-EXT1
Extension for the control of the application heads / switch-off of the heating zones
PROFIBUS Communication Communication interface ICS-PINT
Control of the gear pump
ICS-TIM
External installation of the TRM panel at up to 100 metres distance
Dedicated operating manuals are available for all options.
Concept / 4.1
Appliance overview and functions
21
4.6.3
Wiring diagram For the electrical installation/structure the electric diagram in index 5 must be observed.
Illustration in maximum execution for 8 heated hoses and application heads.
22
Appliance overview and functions functions
Concept / 4.1
4.6.4
Specifications of the ICS-MAIN main control
1
Supply
20…28 VDC, VDC, max. 5 W (outputs without load)
2
Operating temperature
0…60° C, automatic switch-off switch-off at Ti > 65° C at 5…95% relative humidity of air
3
Storage temperature
–40…+85°° C (avoid extreme temperature –40…+85 te mperatures!) s!)
4
Number of tank heating zones
1 or 2 (with premelter)
5
Number of hoses/heads
2, 4, 6 or 8
6
Temperature sensors
Robatech NTC Monitoring of the sensor line for interruption (R > 342 kOhm) and short circuit (R < 21 Ohm)
7
Resolution of temp. measurement
8
Accuracy of temp. feedback control Constancy < 0.5° C - absolute deviation depending on NTC sensor and its offset, respectively.
9
Temperature range
< 0.25° C
20…230° C (tank: 210° C) setting range programmable
10 Activation of the heaters
Pulse width-modulated width-modulated output signal with 1.875 sec. period duration (full wave control)
11 Order of heating up
Programmable All heating zones at the same time or sequential, order: 1. tank - 2. h hoses oses - 3. application heads Release of the heating zone in case of sequential heating if one of the conditions below is met: 1. The reduc reduced ed tem temperature perature o off the heating zone is above 90° C and the heating zone's temperature is below the reduced temperature by less than 10° C. 2. All preceding he heating ating zones mee meett one of the following following conditions: Their temperature is below the nominal (setpoint) temperature by less than 10° C, or the reduced temperature of the heating zone is above 90°C and its temperature is below the reduced temperature by less than 10° C, or
12 Temperature lowering
the heating zone is switched off. Lowered temperature programmable for each heating zone Release of temperature l owering over keyboard, weekly switch clock or input LOW-TEMP (X1.6) of the system interface Status message via output TEMP-LOW (X1.16) of the system interface
13 Automatic switch-off in case of ma- Optional capture of the machine movem movements ents over input T T-chine standstill TRIGGER (X1.4) of the system interface or, if the optional glue application control ICS-EXT1 exists, over the release of glueing. Each edge on the input input T-TRIGGER or release of glueing (ICSEXT1) resets the internal timer. Impulse duration min. 9 msec.
The time until temp. lowering or switch-off is programmable.
Concept / 4.1
Appliance overview and functions
23
14 System interface: outputs
4 DC-decoupled source outputs (PNP) Status indication by LED - supply voltage: 11…27 VDC Output current: max. 150 mA/output, short circuit-proof Output voltage: supply voltage - 1.7 VDC
15 System interface: inputs
5 DC-decoupled inputs - status indication by LED 10…27 VDC, source (PNP), R iinn = 2.7 kOhm
16 System interface:
Power supply for the optional supply of the inputs and/or outputs of the system interface = 24 VDC, I max < 0.3 A
Power supply output 17 Temperature monitoring input
Common for all heating zones Input for temperature switch of heaters (no excess temperature heating) R in in = 5.7 kOhm (24 VDC)
18 Release of airspray valve
Input SSWITCH (X10.1, X10.2) pos. signal s ignal - 20…27 2 0…27 VD VDC, C, Rin = 5 5.7 .7 kOhm
19 Control of airspray valve
Output SVALVE / TANK-EMPTY (twin function with tank fill level output) switched on for as long as the input «SSWITCH» is active and the appliance ready for operation. Output current: max. 0.5 A Output voltage = supply voltage
20 Time switch clock operation (timer) Battery-buffered clock with weekly program Up to two switching times can be programmed per day of the week: Start of temperature lowering, start of normal operation and switching-off of the appliance. Optional switching-off of the time switch clock over control input P-ENABLE1 (X1.7a) of the system interface (parameter 27= 2). 21 Tank fill level supervision
Inputs EMPTY-TANK, FULL-TANK 20…27 VDC, Rin = 5.7 kOhm
22 Tank fill level output
Output SVALVE / EMPTY-TANK EMPT Y-TANK (twin function with airspray valve control) is switched on for as long as the input signal TANKEMPTY is active. Output current: max. 0.5 A Output voltage = supply voltage
23 Safety functions
Monitoring of the correct program sequence with "watchdog". In case of error all outputs are switched off within 0.25 seconds and the program is restarted. Monitoring of the logic supply voltage: all outputs are switched off if the limit value is fallen short of. Monitoring of the ambient temperature Ti with automatic switching-off of all heaters at Ti > 65° C Thermostat input with independent switching-off circuit (switchingoff of the heating supply).
24 Pump emergency-off
Connection for extern external al contact With open contact the supply to the pump is interrupted directly. Contact load: 24 VDC VDC,, max. 0.8 A
25 Parameter storage
EEPROM
26 Battery (clock supply)
Lithium battery type CR 2430 - life span >10 years
24
Appliance overview and functions functions
Concept / 4.1
5 Installation and first commissioning The appliance must be installed and commissioned by a trained and experienced technician. The information provided in this chapter must be read prior to installation under all circumstances. circumstances. For all installation work, make sure you observe the safety references in chapter 2 and also the generally applicable safety saf ety and accident prevention prescriptions. For all installation work on the heated appliance it is an absolute must to wear clothes which cover arms and legs, as well w ell as protective gloves and protective goggles.
Proceed as follows for a successful installation: •
•
Remove the accessories from the cardboard box and put them to one side. Take the appliance from the card board box and check all parts on the basis of the delivery documents. Open the tank lid and take out the wrapped, white cover plate. Remove the folder with the Declaration of Conformity including the sticky tapes from the tank handle.
5.1
Place of positioning
The following requirements must be met: –
The appliance may be operated in sufficiently aerated rooms rooms only
–
Flat, stable positioning surface without vibrations
–
Free-standing position to avoid an accumulation of heat
–
Protect against humidity and splashing water
–
The ambient temperature must must be neither too high nor too low
–
Provide sufficient space for optimal accessibility during operation and maintenance and fo forr the accessories.
Concept / 4.1
Installation and first commissioning
25
–
The appliance must be bolted to the surface it is standing on. For this purpose it features four M8 fastening threads on its underside.
–
Space requirement and dimensions:
Concept Length A Width B Height Tank C
Height Unit D Fastening E Fastening F Distance G Fastening thread Weight
4 545 310 320
8 680 310 320
12 680 385 320
18 806 385 320
601 381 249 83 M8×15 34 kg
570 432 249 125 M8×15 44 kg
570 581 323 40 M8×15 54 kg
570 646 323 83 M8×15 59 kg
All dimensions in [mm]
26
Installation and first commissioning
Concept / 4.1
5.2
Installing the heated hoses
Warning
Danger of splashes and burns The hot adhesive within the system is pressurized up to 100 bar. On opening of the pressure system there is a danger from hot splashes. Install heated hoses only if the system has been relieved of pressure beforehand (see chapter 6.3)! Always wear gloves and protective goggles!
•
•
•
The heated hoses are connected to the distributor block on the rear side of the appliance. Up to 8 heated hoses can be connected depending on the execution of the appliance (see chap. 1.6). The hose connections are offset by 45° and the different unions permit an optimal adaptation on installation. Robatech recommends the use of heated hoses of 8 mm nominal diameter. Heated hose connections
•
A female thread 1/4" is available after removal of the screw plug (1).
•
•
Next, screw the heated hose (3) with the end fea-
A union (2) for connecting the heated hose must now be screwed into this thread hole. Unions are available in different versions (see chapter 11.1).
turing the cable with the connecting plug onto the union. Connecting the heated hose •
•
Tighten the spigot nut with a fork spanner. Don't tighten excessively! The delicate heated hose must not twist, otherwise it will be destroyed. Hold the heated hose firmly by hand or use e.g. a second fork spanner to hold it in position. Tightening the heated hose
Heated hoses are available in different executions and between 0.6 and 9.5 metres long. You will find a complete list of all heated hoses, unions and other mounting material under the accessories in chapter 11.1. The heated hoses must not be laid in cable ducts or under covers without air circulation. An accumulation of heat in certain sections damages the hose and the hotmelt.
Concept / 4.1
Installation and first commissioning
27
5.2.1
Installation examples
Make sure you observe the following installation examples: Wrong
Correct
Remark
Strong bending must be avoided. Remedy: Use an angled screw connection.
Deflections present a danger of kinking. Remedy: Use a saddle or a roller of a suitable diameter.
Butted strains and movements in the length axis as well as a pendulum motions to the side reduce the pressure resistance. Remedy: Install the heated hose with a bend. If the connections connections are not in a straight line to the heated hose, use suitably angled screw connections.
Torsional strains will destroy the heated hose. Remedy: The heated hose must run parallel in its axis and the course of movements must not cause any torsional strains.
28
Installation and first commissioning
Concept / 4.1
Wrong
Correct
Remark
Pulling of rolled heated hoses causes torsional strains and the smallest bending radius is not complied with. Remedy: Unroll the heated hose prior to pulling apart.
Too short a heated hose will cause kinking at its ends. Remedy: A straight section of the length of the hose's diameter (x) must be provided at both ends. The minimum bending diameter amounting to 8 times the hose diameter must be complied with.
Unfavourable installation allows the hose to sag. Remedy: Support the hose with guide elements or suspend it over a roller.
Concept / 4.1
Installation and first commissioning
29
5.2.2
Electrical connection When connecting the heated hoses and the application heads please take note of the chapter 12.1 - Power Pow er distribution and admissible loading. It guarantees a equal pow power er distribution on the three-phase mains.
The plug of the heated hose is plugged into the num bered socket on the rear side of the appliance. The plug of the application head is plugged into the socket at the end of the hose. Compensation factor A ring with an indented number is located on the connecting plug. This compensation factor must be recorded in the list of parameters (in the appendix of this manual) and programmed in the appliance at a later stage (see chapter 6.9.6). Heated hoses without a ring have always a compensation factor of 8.2. Connections at the heated hose
The plugs must not be pulled out or plugged in under load. Failure to comply might damage the heated hose or the appliance.
5.3
Pneumatic connection
–
The piston pump operates pneumatically and must be supplied with compressed compressed air at 6 bar.
–
After removing of the cover the compressed air hose with 8 mm outside diameter is connected to the pressure controller.
–
If another connection has to be used, a R 1/8" connecting thread is available after removal of the plugin connection.
The compressed air must be free of water and dust. No oiled compressed air may be used. The oil would burn into the hot sliding surfaces of the piston pump and thereby damage the pump.
30
Installation and first commissioning
Concept / 4.1
5.4
Electrical connection Electrocution
Danger
Mortal danger exists if live components are touched (operation voltage 400Volt). The protective covers may only be removed if the appliance is disconnected from the power supply.
Connection of the appliance to the power mains and other work on the power circuit is reserved to suitably trained persons exclusively, e.g. electricians or electrical fitters.
5.4.1 •
Checks prior to connection
Check the voltage supply for compliance with the type label 230Volt single phase or 400 Volt 3-phase with neutral conductor
The appliance must not be connected to the mains supply if no neutral conductor is available. In this case the neutral conductor must be created by a star circuit. Make sure you contact Robatech Service before going ahead with this.
•
Watch power consumption according to the type label. Use a supply line of suitable line cross sections and fuses. Connect a main switch in series.
The appliance must be connected and fuse-protected in accordance with local regulations. If the appliance is wrongly connected, there is a danger of electrocution and the appliance might be destroyed. •
•
•
The electrical connection is made on the front bottom of the unit on the orange terminal block (1). Remove the cover (2) after loosening of the two bolts (3) and pull out the cover plate (4) if necessary. Place the end sleeves on the strands and fasten them to the terminal block. At the orifice the cable must be fastened with a cable tie (see also chapter 5.5.5).
Terminal block connection assignment:
Concept / 4.1
Installation and first commissioning
31
5.5
Higher-ranking system controls
The system interface on print ICS-MAIN permits to link the Concept appliance appliance to a higher-ranking system control which can monitor and check the functioning of the ICS I CS control. All inputs and outputs (except X10) are DC-decoupled from the control and wired over terminals.
5.5.1
Data
Outputs
–
X1.13…X1.16
–
4 DC-decoupled source outputs (PNP) with a common supply Status indication with LED
–
Supply voltage: 11…27 VDC
–
Output currennt: max. 150 mA/output, short circuit-proof
–
Output voltage: Supply voltage - 1.7 VDC
Inputs
–
5 DC-decoupled source inputs with common 0V connection
X1.4…X1.7b
–
Status indication with LED
–
10…27 VDC, source (PNP), R iinn = 2.7 kOhm
–
24 VDC power supply for the optional supply of the inputs and/or outputs of the system interface
–
Max. load: Imax < 0.3 A
–
Only active if the optional tank fill level sensor exists and parameter 200: existence extra board ICS-EXT1 is put to OFF
–
Twin function with spray valve output
–
Status indication with LED
–
24 VDC, source, Imax < 0.5 A, short circuit-proof
–
Connection for external emergency-off contact; with open contact the sup ply to the pump is interrupted directly
–
Contact loading: 24 VDC, I max < 0.8 A
Power supply output
Tank fill level ouput
TANK-EMPTY
Pump emergency-off
P-EMOFF at X33
5.5.2
Signals
The connection terminals are numbered and located at the bottom of control pr print int ICS-MAIN.
X1
32
Designation
1 2 3
0V + 24 VDC INPGND
4
H-ENABLE
I / O
LED
Output Output Input Input
D16
Function
Power supply 0 V Power supply 24 VDC Common 0V connection of the inputs H-ENABLE, T-TRIGGER, LOW-TEMP and P-ENABLE If switched off and parameter 26 = On, all heaters are switched off
Installation and first commissioning
Concept / 4.1
X1
Designation
I / O
LED
Function
5
T-TRIGGER
Input
D 17
6 7a
LOW-TEMP P-ENABLE1
Input Input
D 18 D 19
7b 8 9 10, 11 12 13 14 15
P-ENABLE2 0V + 24 VDC OUTGND OUTVIN ON READY ALARM
Input Output Output Input Input Output Output Output
D 30
D 23 D 24 D 25
16
TEMP-LOW
Output
D 26
Standstill supervision, each edge (min. 9ms) resets the su pervision timer Activation of temperature lowering If parameter 27 = 1 and input is switched off = pump and optional pressure build-up valve valve are switched off If parameter 27 = 2 and input is switched on = timer function switchs off and device switchs on no function Power supply 0 V Power supply 24 VDC Output supply 0 V Output supply 12..24 VDC Heaters released; inverse function of LED «0(off)» Appliance ready for op.; same function as LED «Ready «Ready» » Error; function like LED «Error» except for error E102/E103 Temperature lowering active, same function as LED «T low»
The connections 1+8, 2+9 and 10+11 are connected to each other in each case X10
1 2 3 4
X11/X12
1 2 3 4 X23
Designation
SSWITCH + 24 VDC 0V SVALVE / TANK-EMPTY
Designation
0V + 24 VDC EMPTY-TANK FULL-TANK Designation
I / O
LED
Function
Input Output Output Output
D 22
Release of the spray gun Power supply 24 VDC Power supply 0 V Tank fill level too low or activation of spray valve (twin function!) Tank fill level display only active if the sensor exists and parameter 200 is set to «OFF».
I / O
LED
Function
Output Output Input Input
D 20 D 21
Power supply 0 V Power supply 24 VDC if input is switched on = Tank empty if input is switched on = Tank overcharged
I / O
LED
Function
D 29
1
0V
Output
Power supply 0 V
2
+ 24 VDC
Output
Power supply 24 VDC
3
PAR-LOCKED1
Input
D31
not active
4
PAR-LOCKED2
Input
D32
if parameter 32 = «1 or 2» and input is switched on = Blockage of data entry
X33
Designation
I / O
LED
Function
1 2
P-EMOFF1 P-EMOFF2
Output Input
Concept / 4.1
Connection for an external emergency pump stop. Open contacts interrupt the 24VDC supply to the pump drives.
Installation and first commissioning
33
5.5.3
– – – – –
34
Connection of PLC control
Fuse 1AF Part No.111202; supplier e.g. Schurter type SP 0001.1004 If activation is effected by a PLC control, the voltage supply of the PLC control must be wired to print ICSMAIN. GND of the PLC control is put on terminal X1, connection 10, the switching voltage of the PLC control is put on terminal X1, connection 12. All connections on terminal X10 are not potential-segregated. Optocoupler or relay contact must be connected in series under all circumstances. For wiring, please observe the remarks r emarks concerning electromagnetic electromagnetic compatibility (EMC) in chapter 5 5.5.5. .5.5.
Installation and first commissioning
Concept / 4.1
5.5.4
–
– –
Connection of relay control
If activation and evaluation are effected over relay contacts without potential, the voltage required for switching can be obtained from connection 2 on terminal X1. In this case the connections 8 and 10 as well as 9 and 12 on terminal X1 are to be connected. All connections on terminal X10 are not potential-segregated. Optocoupler or relay contact must be connected in series under all circumstances. For wiring, please observe the remarks r emarks concerning electromagnetic electromagnetic compatibility (EMC) in the next chapter.
Concept / 4.1
Installation and first commissioning
35
5.5.5
Wiring in compliance with EMC
The electromagnetic compatibility or compatibility or abbreviated EMC refers to the ability of an appliance to correctly operate in an environment with other electrical devices without itself generating any interferences. Correct wiring of the control lines is an important part of this. Please observe the following points:
Electrocution
Danger
The appliance must be separated from the power mains before any connecting cables are connected. Touching of live components means mortal danger.
•
Use only shielded cables which are skinned as illustrated on the right. The dimension X depends on the position of the terminal. Stripped connecting cable
•
•
•
The cable is fed through the base plate into the electrical cabinet. The free line shield is connected to the appliance housing by means of a cable tie. The line shield must be earthed at the cable's beginning and at its end. This is the only way in which an attenuation of the electromagnetic interference fields is provided. A shield connected on one side only offers only poor shielding, and a shield which is not connected at all suppresses no interference fields. Suitable EMC cable connection
5.6
Installation of accessories and options
Normally, accessories and options are installed at the Robatech works before the appliance is delivered. However, subsequent installation is also possible. The installation and operation of accessories and options such as −
− − − −
application control ICS-IK incl. control accessories like encoder, photoelectric cells, valve cables, etc. external installation of the operating unit gear pump tank fill level supervisions pressure relief
are described in the pertaining manuals. A detailed overview of the accessories can be found in chapter 11; Accessories.
36
Installation and first commissioning
Concept / 4.1
5.7
First commissioning To be able to work safely and perfectly and to avoid bodily and material damage, the appliance must be in impeccable condition. The following items must be checked prior to first commissioning: commissioning:
•
Fit the warning stickers in the local language. In standard execution the appliance is delivered with warning labels in German. The plastic folder contains labels in English and French. The ones in the appropriate language can be stuck over the existing labels.
•
•
•
•
Adapt the tank lid if necessary. For optimal accessibility the tank lid can be turned by 180 degrees. Unscrew the stop plate and press the securing ring off the shaft using a screwdriver. Remove the tank lid and install it on the opposite side. Are power connection and all electrical connections correctly installed? Compressed air available and connected to the piston pump? Set the pressure controller to 0 bar. bar . Heated hoses correctly fitted and application systems (application head, hand gun, etc.) installed in accordance with the pertaining instructions? Are all glue exits locked which are not used?
If all above points are complied with, the appliance app liance can be switched on for a short test run: •
Switch the appliance on. All indications must light up for two seconds and the display at the bottom right shows the program version. Check the program version for concurrence with this operating manual.
•
•
Next, switch the appliance off again. Programming of the appliance and the functions for production are de-
If no temperatures are programmed yet (standard setting) LED «Ready» will then be lit. If temperature values are already entered, LED «Tr supply to pump interrupted) X33.1 A P-EMOFF1 X33.2 E P-EMOFF2
IC3
EPROM
IC5
EEPROM (only with optional hotmelt application control ICS-IK)
BAT1
Battery 3V minimum voltage 2.6Volt, Art. No. 111359
A = output, E = input, Dxx = luminous diode, Xxx = connector or terminal After a short circuit the supply voltage switches itself off automatically. The 24V supply voltage on the MAIN print is switched on again by switching off and on again after at least 10 seconds. – If the supply voltage does not switch itself on automatically, check the supply from the power supply unit at connector X3. Next, the fuse F2 on print PWDR3 must be checked before finally checking the fuse of the power supply unit. The power supply unit is behind the MAIN print. For checking and replacing of the power supply unit's fuse it is necessary to remove the entire MAIN print.
–
72
Repair
8.7.2
ICS-PWR1 Tank heating
Heating function LED D1 is lit if the tank heating zone is switched on by the control ICS-MAIN. If the LED is lit permanently and the tank heating has not reached the nominal temperature after 60 minutes, it is possible that the fuses F1…F3 or the
heating elements are defective. Fuses The fuses F1, F2 and F3 protect the pow power er out puts L1, L2 and L3 to the 3 heating elements. A defect of the fuses is not indicated by the LED.
X1, X2
Supply
X1.1
E
N
X1.2 X1.3
E E
W V
X1.4
E
U
X3
Connection to print ICS-MAIN
X4
Connection heater
X5
X4.1 X4.2
A A
N (optional) T (W-wired)
X4.3
A
S (V-wired)
X4.4
A
R (U-wired)
Connection temperature sensor
X5.1
–
NTC –
X5.2 X5.3
–
NTC + empty
X5.4 X6
empty
Connection excess temperature switch (contact open = excess temperature)
X6.1
–
OTMP1
X6.2
–
OTMP2
D1
LED Heating on
F1
Fuse heating output T
12.5AF Part No.113808
F2
Fuse heating output S
12.5AF Part No.113808
F3
Fuse heating output R
12.5AF Part No.113808
A = output, E = input, Dxx = luminous diode, Xxx = connector or terminal
Concept / 4.1
Concept / 4.1
Repair
8.7.3
ICS-PWR2 Heating of heated hoses and application heads
Two executions exist: ICS-PWR2/4 For 4 heated hoses and 4 application heads ICS-PWR2/2 For 2 heated hoses and 2 application heads
Missing are F5 to F8, D5 to D8 as well as X2, 6, 7, 10 and 11. Fuses and LED function checking One fuse and one LED are assigned to each heated hose and application head. LED ”D4" indicates, for example, that the application head 2, or application head 6 in case the second PWR2 is installed, is switched on.
If one of the LEDs is switched on continuously, the heating zone is – in the heating-up phase, or – the heating element in the heating zone is defective, – the supply line is interrupted, or – the fuse is defective X1, X2
Supply
X1.1
E
N
X1.2
E
W
X1.3 X1.4
E E
V U
X3
Connection to print ICS-MAIN
X4
Connection heaters 1, 2 (heated hose 1(5), application head 1(5))
X5
X6
X7
X4.1
A
N
X4.2 X4.4
A A
N HEATER 1 (W-wired)
X4.3 A HEATER 2 (W-wired) Connection heaters 3, 4 (heated hose 2(6), application head 2(6)) X5.1 A N X5.2
A
N
X5.4 X5.3
A A
HEATER 3 (W-wired) HEATER 4 (W-wired)
Connection heaters 5, 6 (heated hose 3(7), application head 3(7))
X6.1 X6.2
A A
N N
X6.4
A
HEATER 5 (V-wired)
X6.3
A
HEATER 6 (V-wired)
Connection heaters 7, 8 (heated hose 4(8), application head 4(8))
X7.1
A
N
X7.2
A
N
X7.4 X7.3
A A
HEATER 7 (U-wired) HEATER 8 (U-wired)
73
74
Repair
X8
X9
X10
X11
Connection temperature sensors 1, 2
X8.1
–
NTC1 –
X8.2 X8.3
– –
NTC1 + NTC2 –
X8.4
–
NTC2 +
Connection temperature sensors 3, 4 X9.1 – NTC3 –
X9.2
–
NTC3 +
X9.3 X9.4
– –
NTC4 – NTC4 +
Connection temperature sensors 5, 6
X10.1 X10.2
– –
NTC5 – NTC5 +
X10.3
–
NTC6 –
X10.4
–
NTC6 +
Connection temperature sensors 7, 8
X11.1
–
NTC7 –
X11.2 X11.3
– –
NTC7 + NTC8 –
D1…D8
X11.4 – NTC8 + LED Heating 1…8 on
F1…F8
Fuse heating 1…8
5AF Part No. 112568
A = output, E = input, Dxx = luminous diode, Xxx = connector or terminal
8.7.4 X1
ICS-PUS Piston pump control Supply X1.1
X1.2 X2
0 VDC 24 VDC
Connection valve 1 (bottom valve)
X2.1 X3
E E A
0 VDC
X2.2 A 24 VDC-wired Connection valve 2 (top valve) X3.1 A 0 VDC X3.2 A 24 VDC-wired
D2
LED «Piston at bottom»
D3
LED «Piston at top»
D4
LED «Valve 2 on»
D5
LED «Valve 1 on»
A = output, E = input, Dxx = luminous diode, Xxx = connector or terminal
Concept / 4.1
Concept / 4.1
Repair
8.7.5
ICS-PWRD1 Power distribution
Supply 1LNPE, 230VAC, 50/60Hz, I
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