Romer PROTON II User Manual
1
Manual coating equipment
PROTON II
Manufacturer of high quality equipment for powder coating
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Spis treści
General safety regulations ............................................................................................................................. 4
Safety symbols (pictograms) ...................................................................................................................... 4
Static charges ......................................................................................................................................... 7
Grounding .............................................................................................................................................. 7
PROTON II "V" ............................................................................................................................................... 9
Scope of delivery ........................................................................................................................................ 9
PROTON II..................................................................................................................................................... 10
Operating modes ..................................................................................................................................... 11
Technical Data .............................................................................................................................................. 12
PROTON II Manual gun control unit ........................................................................................................ 12
Start-up and operation ................................................................................................................................ 13
PROTON II CONTROL PANEL ........................................................................................................................ 16
Initial start-up............................................................................................................................................... 19
Daily start up ............................................................................................................................................ 20
Remote control by PROTON II manual gun .............................................................................................. 24
Error diagnosis of the software.................................................................................................................... 25
Spare parts list PROTON II ............................................................................................................................ 28
Ordering spare parts ................................................................................................................................ 28
PROTON II Manual gun control unit ............................................................................................................ 29
Manual gun control unit - outside rear wall ........................................................................................ 30
Manual gun control unit - outside rear wall ........................................................................................ 31
PROTON II manual powder gun ................................................................................................................... 33
Scope of delivery ...................................................................................................................................... 33
Technical Data .............................................................................................................................................. 34
PROTON II manual powder gun ............................................................................................................... 34
Start-up and operation ................................................................................................................................ 35
Connecting guide ..................................................................................................................................... 35
Function check ......................................................................................................................................... 37
Start-up .................................................................................................................................................... 38
Maintenance and cleaning ........................................................................................................................... 39
Daily maintenance ................................................................................................................................... 39
Weekly maintenance ............................................................................................................................... 39
Cleaning........................................................................................................................................................ 40
Troubleshooting guide ................................................................................................................................. 43
General information ................................................................................................................................ 43
Spare parts list PROTON II ............................................................................................................................ 44
Ordering spare parts ................................................................................................................................ 44
Manufacturer of high quality equipment for powder coating
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PROTON II manual powder gun - spare parts list ........................................................................................ 45
PROTON II manual powder gun - spare parts list ........................................................................................ 46
PROTON II manual powder gun - spare parts list (cont.) ............................................................................. 47
PROTON II manual powder gun - accessories .............................................................................................. 48
PROTON II flat jet nozzles - overview....................................................................................................... 48
PROTON II round jet nozzles - overview .................................................................................................. 49
Powder hose connectors - overview........................................................................................................ 50
Injector G2 ................................................................................................................................................... 51
Principle of the injector and influence of ................................................................................................ 51
supplementary air ................................................................................................................................... 51
Powder volume setting table for G2 injector .......................................................................................... 52
Guide values for PROTON /PROTON II with G2 injector ...................................................................... 53
Cleaning and maintenance .......................................................................................................................... 54
Injector cleaning....................................................................................................................................... 54
Cleaning the check valves ........................................................................................................................ 55
Troubleshooting guide ................................................................................................................................. 56
Problem fixing .......................................................................................................................................... 56
Spare parts list G2 ........................................................................................................................................ 57
Ordering spare parts ................................................................................................................................ 57
G2 powder injector (G2 type) - spare parts list ........................................................................................... 58
G2 powder injector (G2 type) - spare parts ............................................................................................. 59
Manufacturer of high quality equipment for powder coating
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General safety regulations
Safety symbols (pictograms)
The following warnings with their meanings can be found in the Ge-ma
operating instructions. The general safety precautions must also be
followed as well as the regulations in the operating instructions.
DANGER!
Danger due to live electricity or moving parts Possible consequences:
Death or serious injury
ATTENTION!
Improper use of the equipment could damage the machine or cause it to
malfunction. Possible consequences: Minor injuries or damage to equipment
NOTE!
Useful tips and other information
Manufacturer of high quality equipment for powder coating
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General
information
General
danger
The manual coating equipment is built to the latest specification and
conforms to the recognized technical safety regulations and it is designed for the normal application of powder coating.
Any other use is considered as non-conform. The manufacturer is not responsible for any damage resulting from this - the risk for this is assumed
by the user alone! If the manual coating equipment is to be used for
other purposes or other substances outside of our guidelines, then
ROMER should be consulted.
Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of conformity of use.
The relevant accident prevention regulations, as well as other generally
recognized safety regulations, occupational health and structural regulations are to be observed.
Furthermore, the country-specific safety regulations also must be
ob-served.
Further safety and operation notices will be found on the
accompanying CD or on the homepage http://romerpp.pl
The start-up is forbidden until it has been established that the manual coating equipment has been set up and wired according to the EU guidelines for machinery.
Unauthorized modifications to the manual coating equipment exempts
the manufacturer from any liability from resulting damages or accidents.
The operator must ensure that all users do have the appropriate training
for powder spraying equipment and are aware of the possible sources of
danger.
Any operating method, which will negatively influence the technical safety
of the powder spraying equipment, is to be avoided.
For your own safety, only use accessories and attachments listed in
the operating instructions. The use of other parts can lead to risk of
injury. Only original ROMER spare parts should be used!
Repairs must only be carried out by specialists or by authorized ROMER
service centers. Unauthorized conversions and modifications can lead to
injuries and damage to the equipment, and the ROMER guarantee
would no longer be valid.
These general safety regulations must be read
and understood mandatory be-fore start-up!
Manufacturer of high quality equipment for powder coating
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Electrical
danger
Explosion hazard
Slip hazard
The connecting cables between the control unit and the spray gun must
be installed in such a way, that they cannot be damaged during the operation. Please observe the local safety regulations!
The plug connections between the powder spraying equipment and the
mains should only be removed when the power supply is switched off.
All maintenance activities must take place when the powder spraying
equipment is switched off.
The powder coating equipment may be able to be switched on only if the
booth is in operation. If the booth stops, the powder coating device must
switch off too.
The control units for the spray guns must be installed and used in
zone 22. Spray guns are allowed in zone 21.
Only original ROMER spare parts will guarantee that the explosion
protection will be preserved. If damages occur by using spare parts
from other manufacturers, the warranty or compensation claim is void!
Conditions leading to dangerous levels of dust concentration in the powder spraying booths or in the powder spraying areas must be avoided.
There must be sufficient technical ventilation available, to prevent a dust
concentration of more than 50% of the lower explosion limit (UEG = max.
permissible powder/air concentration). If the UEG is not known, then a
value of 10 g/m³ should be considered (see EN 50177).
All unauthorized conversions and modifications to the electrostatic spraying equipment are forbidden for safety reasons.
No safety devices should be dismantled or put out of operation.
The operating and job instructions has to be written in an understandable
form and in the language of the persons employed, and has to be announced in a suitable place in the working area.
Powder lying on the floor around the powder spraying equipment is a potentially dangerous source of slipping. Booths may be entered only in the
places suitable for it.
Manufacturer of high quality equipment for powder coating
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Observe the
grounding regulations
Fire and
smoke prohibition
The stay for
persons with
cardiac pacemakers
is forbidden
Static charges
Static charges can have the following consequences: Charges to people,
electric shocks, sparking. Charging of objects must be avoided by a proper grounding.
Grounding
All electricity conducting parts found in the workplace of 5 meters around
each booth opening, and particularly the objects to be coated, have to
be grounded. The earthing resistance of each object must amount to
maxi-mally 1 MOhm. This resistance must be checked/tested regularly
when starting work.
The condition of the work piece attachments, as well as the hangers,
must guarantee that the work pieces remain grounded. The appropriate
measuring devices must be kept ready in the workplace, in order to
check the grounding.
The floor of the coating area must conduct electricity (normal concrete is
generally conductive).
The supplied grounding cable (green/yellow) must be connected to the
grounding screw of the electrostatic manual powder coating equipment.
The grounding cable must have a good metallic connection with the coating booth, the recovery unit and the conveyor chain, respectively with the
suspension arrangement of the objects.
Smoking and igniting fire are forbidden in the entire plant area! All sparkgenerating works are forbidden!
As a general rule for all powder spraying installations, persons with pacemakers should never enter high voltage areas or areas with electromagnetic fields. Persons with pacemakers should not enter areas with
powder spraying installations!
Manufacturer of high quality equipment for powder coating
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Photographing with flashlight can lead to unnecessary releases and/or
disconnections by safety devices.
Photographing with
flashlight is forbidden
Disconnect the plugs before the machines are opened for
maintenance or repair.
The plug connections between the powder spraying equipment and the
mains should only be removed when the power supply is switched off.
Disconnect from mains
before maintenance
works take place
As far as it is necessary, the operating firm must ensure that the
operat-ing personnel wear protective clothing (e.g. facemasks).
The operating personnel must wear electrically conductive footwear
(e.g. leather soles).
The operating personnel should hold the gun with bare hands. If gloves
are worn, these must also conduct electricity.
These general safety regulations must
be read and understood mandatory
be-fore start-up!
Manufacturer of high quality equipment for powder coating
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PROTON II "V"
Scope of delivery
1. The control unit
2. Manual Gun
3. Injector
4. Stand with holder
5. Suction pipe / fluidized bed
6. Vibrating table
7. Carton of paint
8. Swivel arm sleeve
9. The filter (not visible)
10. Gun holder
11. Handle on snake powder
12. Quick couplings
13. Shelf
14. Circle Rubber
15. Rotary wheel
max. 10 bar / 145 psi
min. 6 bar / 87 psi
100-240 VAC, 50-60 Hz
Manufacturer of high quality equipment for powder coating
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PROTON II
1. The control unit
2. Couplings
3. Injector
4. The paint
5. Stand with holder
6. The rotary wheel
7. Circle Plastic
8. Reducing air filter
9. Holder powder hose (not visible)
10 Gun
11. The fluidizing plate
Manufacturer of high quality equipment for powder coating
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Operating modes
The PROTON II Manual gun control unit can be operated with two
operating modes. According to the selected application mode, the spray
voltage and the spray current are automatically adjusted and limited.
Predefined operating mode (Preset mode)
The PROTON II Gun control unit provides three predefined application
modes (flat parts, complicated parts and recoat parts already painted one
time). When operating in this mode, the spray voltage and spray current
are au-tomatically set and limited.
In this operating mode, current (µA) and high voltage (kV) are preset,
powder and air volume can be adjusted and saved. The powder and
air volume are stored separately for each predefined application mode.
User-defined operating mode (Program mode)
In this operating mode, 20 individually definable programs (P01-P20)
are available. These programs are automatically saved and can be
recalled again as the application requires.
The values for current, high voltage, powder output, total air, electrode
rinsing air and fluidizing air (if available) can be set as needed for a given
application.
Note:
The specified values in the 20 programs and 3 application modes are
saved automatically, without confirmation, after a two second delay
and the display changes from preset values to actual values!
Manufacturer of high quality equipment for powder coating
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Technical Data
PROTON II Manual gun control unit
Connectable guns
PROTON II
connectable
PROTON II
yes
Attention:
The PROTON II Manual gun control unit can only be used with
the specified gun types!
Electrical data
PROTON II
Data
Mains input voltage
100-240 VAC
Operating frequency
50-60 Hz
Input power (without vibrator)
40 VA
Nominal output voltage (to the gun)
max. 12 V
Nominal output current (to the gun)
max. 1 A
Vibrator connection and power (on the Aux
110/220 VAC
output)
max. 100W
Protection type
IP54
Temperature range
0°C - +40°C
(+32°F - +104°F)
Max. operating temperature
85°C (+185°F)
Manufacturer of high quality equipment for powder coating
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Start-up and operation
PROTON II Gun control unit - connections on the rear wall
Connection
Description
1.1
Air Supply IN
Compressed air connection (6-10 bar / 87-145 PSI)
2.1 Power IN
Mains cable connection (100-240 VAC)
2.2
Aux
Vibration motor connection for PROTON II
2.3 Gun
Gun cable connection
1.5
Fluidizing air connection
1.4
Electrode rinsing air connection
1.3
Supplementary air connection
1.2
Conveying air connection
Grounding connection
Manufacturer of high quality equipment for powder coating
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1. Check the compressed air connection from filter unit to con-trol
unit. Connect the compressed air supply hose from the
compressed air circuit directly to the filter unit main connec-tion
on the rear side of the equipment (1/4" female BSP)
Note:
The compressed air must be free from oil and water!
2. Connect the black hose for fluidizing air (electrically conductive) to the output 1.5 on the rear side of the control unit
3. Connect the grounding cable to the control unit with the
grounding screw, and the 5 m long grounding cable with the
clamping clip to the booth or the conveyor. Check ground
connections with Ohm meter and ensure 1 MOhm or less
4. Connect the gun cable plug to the socket 2.3 on the rear side
of the control unit
5. Connect the rinsing air hose to the electrode rinsing air output 1.4 and to the powder gun
6. Insert the injector, connect the powder hose to the injector
and to the powder gun
7. Connect the red hose for conveying air to the corresponding
output 1.2 on the rear side of the control unit and to the injector
8. Connect the black hose for supplementary air to the corresponding output 1.3 on the rear side of the control unit and
to the injector (this hose is electrically conducting)
9. Connect the mains cable to the 2.1 Power IN plug and tighten with provided screw
Note:
If no vibration motor (PROTON II) is connected, the 2.2 Aux output
is to be locked tightly with the provided protection cap!
Manufacturer of high quality equipment for powder coating
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Connection guide
Manufacturer of high quality equipment for powder coating
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PROTON II CONTROL PANEL
Manufacturer of high quality equipment for powder coating
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Symbol
Function
T1-T8
Buttons nominal values and system parameters
T9 (Select)
Selecting the display level
T10-T11
Changing the program
T12
The choice of programs that can be set (max.20)
T13
The operation mode of painting flat details (factory)
T14
The operation mode of painting places hard to reach (factory)
T15
Mode of operation for repainting (factory)
T16
Enable / disable fluidization air
Enable / disable the vibrator and fluidization
Turn off the on / off fluidization
Switching modes cleaning gun (press and hold for at least 3 sec.)
S1/S2
Turn on / off power supply unit (On / Off)
Manufacturer of high quality equipment for powder coating
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Element
Function
A1-A4
Displays the current or programmed (fixed) values and parameters of
voltage, current, air and individual programs of the operator (painter)
A5
Displays the program numbers, error codes, and blow gun
L1
The amount of paint (shown in%)
L2
The value of total air (shown in Nm3 / h)
L3
Current (displayed in uA)
L4
The air for fluidization (shown in Nm3 / h)
L5
High voltage (displayed in kV)
L6
The value of air blowing electrodes (shown in Nm3 / h)
L7
Switch vibrator / fluidization
L13
Permanent program for painting detail flat
L14
Permanent program for painting hard to reach places
L15
An ongoing program for repainting
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