WAGNER PXM, PI-F1, Hi-Coat ED, IP 5000, EPG S2 Operating And Assembly Manual

...

Download

Translation of the Original Operating and Assembly Manual

PXM

Powder Center

Version 08 / 2015

P_02519P_0251

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

Table of Contents

1 ABOUT THESE INSTRUCTIONS 7

1.1 Preface 7

1.2 Warnings, Notices, and Symbols in this Operating Manual 7

1.3 Languages 8

1.4 Abbreviations 8

1.5 Terminology for the Purpose of this Manual 9

2 CORRECT USE 10

2.1 Device Type 10

2.2 Type of Use 10

2.3 Use in Potentially Explosive Areas 10

2.4 Safety Parameters 10

2.5 Processible Working Materials 11

2.6 Reasonably Foreseeable Misuse 11

2.7 Residual Risks 11

PXM

3 IDENTIFICATION 12

3.1 Explosion Protection Identi cation 12

3.2 Permissible Device Combinations 12

3.3 Type Plate 12

3.4 Note on the Ex-Zone Classi cation by the Operator 13

4 GENERAL SAFETY INSTRUCTIONS 14

4.1 Safety Instructions for the Operator 14

4.1.1 Electrical Devices and Equipment 14

4.1.2 Personnel Quali cations 14

4.1.3 Safe Work Environment 14

4.2 Safety Instructions for Sta 15

4.2.1 Safe Handling of WAGNER Powder Spray Devices 15

4.2.2 Grounding the Device 15

4.2.3 Product Hoses 15

4.2.4 Cleaning 16

4.2.5 Handling Powder Lacquers 16

5 DESCRIPTION 17

5.1 Components 17

5.1.1 Version with Integrated Filter 18

5.1.2 Version for Final Filter 19

5.1.2 Version with Ultrasonic Sieve 20

5.2 Mode of Operation 21

5.3 Protective and Monitoring Equipment 21

5.4 Scope of Delivery 22

5.4.1 Design Variants of the PXM Powder Center 22

5.4.2 Type with Ultrasonic Screening Unit 23

5.4.3 Installation Dimensions for Ultrasonic Screening Unit 23

5.5 Technical Data 24

5.6 Controls 25

5.7 Screen Layout of the Touch Screen 26

5.8 Explanation of the Screen Page Numbers 27

5.9 Inputs on the Touch Panel 28

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

Table of Contents

5.10 Displays on the Warning Lamp 28

5.11 User Rights 29

6 ASSEMBLY AND COMMISSIONING 30

6.1 Training the Assembly Sta 30

6.2 Storage Conditions 30

6.3 Installation Conditions 30

6.4 Transportation 31

6.5 Assembly and Installation 32

6.6 Grounding 37

6.7 Safety Checks 37

6.8 Commissioning 38

6.9 Standard Settings 39

6.9.1 Machine Parameters Operation 39

6.9.2 Machine Parameter Cleaning 40

6.9.3 CAN Addresses for MCM System 41

6.9.4 EPG S2 Settings 42

6.10 Function Test 44

PXM

7 OPERATION 46

7.1 Training the Operating Sta 46

7.2 Safety Instructions 46

7.3 Touch Screen Operation Standard Equipment 47

7.3.1 Equipment with Final Filter 47

7.3.2 Equipment with Integrated Exhaust System 48

7.4 Set Language 49

7.5 Logging a User On/O 50

7.6 Starting/Stopping Coating 51

7.6.1 Paint Change Components 52

7.6.2 Cleaning Positions Powder Hoses 53

7.7 Con guring the Powder Center 54

7.7.1 Settings 55

7.7.2 Machine Parameters Operation 56

7.7.3 Machine Parameter Cleaning 62

7.7.4 Machine Parameters Diagnosis 64

7.7.5 System 66

8 CLEANING AND MAINTENANCE 69

8.1 Cleaning 69

8.1.1 Cleaning Sta 69

8.1.2 Safety Instructions 69

8.2 Paint Change 70

8.2.1 Paint Change Components 70

8.2.2 Cleaning Positions Powder Hoses 71

8.2.3 Cleaning Functions 72

8.2.4 Cleaning Parameters 72

8.2.5 Start Cleaning (Example: Pro Tech M) 73

8.2.6 Cleaning/Paint Change on the PXM with Ultrasonic Sieve 82

8.3 Maintenance 85

8.3.1 Maintenance Sta 85

8.3.2 Safety Instructions 85

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

Table of Contents

8.3.3 Maintenance Procedures 86

8.3.4 Safety Checks 87

8.3.4.1 Grounding Check 87

9 TROUBLESHOOTING AND RECTIFICATION 88

9.1 Fault Messages 88

9.2 Types of Fault Messages 89

9.3 Current 89

9.4 History 90

10 REPAIR 93

10.1 Repair Personnel 93

10.2 Safety Instructions 93

11 FUNCTION TEST AFTER THE REPAIR 95

12 INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: 2010 96

PXM

13 DISASSEMBLY AND DISPOSAL 99

14 ACCESSORIES 100

15 SPARE PARTS 103

15.1 How Can Spare Parts Be Ordered? 103

15.2 Workstation 22 Injectors 104

15.3 Workstation 20 Injectors with Fluidization 106

15.3 Workstation 34 Injectors 108

15.4 Cylinder Workstation (22 Injectors) 110

15.5 Cylinder Workstation (34 Injectors) 111

15.6 Scraper Assembly Intake Tubes 112

15.7 Cleaning System Tank Version (22 Injectors) 114

15.8 Cleaning System Box Version (22 Injectors) 116

15.9 Vibration Table 118

15.10 Feed lance 120

15.11 Vibrating Table Fresh Powder 122

15.12 Compressed Air Tank for 22 Injectors (1 Outlet) 123

15.13 Compressed air tank for 22 injectors 124

15.14 Compressed Air Tank for 34 Injectors 125

15.15 Pressure Regulator, Complete 126

15.12 Powder Tank, Fluidized (22 Injectors) 127

15.13 Final Filter Adapter 128

15.14 Exhaust System Throttle Valve 130

15.15 Exhaust system throttle valve (version with US sieve) 132

15.16 Housing 134

15.17 Control Unit Cabinet (1 IP 5000) 136

15.18 Control Unit Cabinet (2 IP 5000) 138

15.19 Control Unit Cabinet (18 EPG) 140

15.20 Control Unit Cabinet Control Panel 142

15.21 LED Lamp 1500 143

15.22 LED Lamp 700 144

15.23 Final Filter 145

15.24 PI-F1 Powder Injector 147

15.25 PI-P1 Powder Injector 148

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

Table of Contents

15.26 HiCoat-ED Pump P 149

15.27 HiCoat-ED Pump F 150

15.28 Fresh Powder Feed Unit 151

15.29 Ultrasonic Screening Unit 152

15.30 Level Sensor 153

16 WARRANTY DECLARATION AND DECLARATION OF INCORPORATION 154

16.1 Important Notes Regarding Product Liability 154

16.2 Warranty Claim 154

16.3 Declaration of Incorporation (Statement of Conformity) 155

17 ELECTRICAL CONNECTION PLANS 158

PXM

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

1 ABOUT THESE INSTRUCTIONS

1.1 PREFACE

The operating manual contains information about safely operating, maintaining, cleaning and repairing the device. The operating manual is part of the device and must be available to the operating and service personnel. The device may only be operated by trained personnel and in compliance with this operating manual. Operating and service personnel should be instructed according to the safety instructions. This equipment can be dangerous if it is not operated according to the instructions in this operating manual.

PXM

1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL

Warning instructions in this operating manual highlight particular dangers to users and to the device and state measures for avoiding the hazard. These warning instructions fall into the following categories:

Danger - immediate risk of danger. Non-observance will result in death or serious injury.

Warning - possible imminent danger. Non-observance may result in death or serious injury.

Caution - a possibly hazardous situation. Non-observance may result in minor injury.

DANGER

This notice warns you of a hazard!

Possible consequences of not observing the warning instructions. The signal word indicates the hazard level.

The measures for preventing the danger and its consequences.

WARNING

This notice warns you of a hazard!

Possible consequences of not observing the warning instructions. The signal word indicates the hazard level.

The measures for preventing the danger and its consequences.

CAUTION

This notice warns you of a hazard!

Possible consequences of not observing the warning instructions. The signal word indicates the hazard level.

The measures for preventing the danger and its consequences.

Notice - a possibly hazardous situation. Non-observance may result in damage to property.

This notice warns you of a hazard!

Possible consequences of not observing the warning instructions. The signal word indicates the hazard level.

The measures for preventing the danger and its consequences.

NOTICE

Note - provides information about particular characteristics and how to proceed.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

1.3 LANGUAGES

The operating manual is available in the following languages:

Language: Order No. Language: Order No. German 2350371 English 2350372 French 2361466 Italian 2361468 Spanish 2361471 Russian 2361472 Chinese 2361473

1.4 ABBREVIATIONS

Number of pieces Position Marking in the spare parts lists

Order No. Order number

Spare part FP Fresh powder RP Reclaimed powder

Version with integrated suction

Version with  nal  lter

PXM

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL

Cleaning Manual cleaning of devices and device parts with cleaning agent Flushing Internal  ushing with compressed air of parts carrying paint

Sta quali cations

Trained person Is instructed in the tasks assigned to him/her, the potential risks

associated with improper behavior as well as the necessary protective devices and measures.

Electrically trained person

Electrician Can assess the work assigned to him/her and detect possible

Skilled person A person, who, based on his/her technical training, experience In accordance with

TRBS 1203 (2010)

Is instructed by an electrician about the tasks assigned to him/her, the potential risks associated with improper behavior as well as the necessary protective devices and measures.

hazards based on his/her technical training, knowledge and experience in relevant provisions.

and recent vocational experience, has su cient technical knowledge in the areas of explosion protection, protection from pressure hazards and electric hazards (if applicable) and is familiar with the relevant and generally accepted rules of technology so that he/she can inspect and assess the status of devices and coating systems based on workplace safety.

PXM

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

2 CORRECT USE

2.1 DEVICE TYPE

Powder center for feeding  uidized powder lacquers

2.2 TYPE OF USE

The PXM powder center is used to feed  uidized powder lacquers from a powder tank (including original tank) to several guns at the same time.

PXM

2.3 USE IN POTENTIALLY EXPLOSIVE AREAS

The PXM powder center is intended for construction outside of the dust Ex-zone (Zone 22).

2.4 SAFETY PARAMETERS

WAGNER accepts no liability for any damage arising from incorrect use.

Use the device only to work with the products recommended by WAGNER. Operate only the device as a whole. Do not deactivate safety  xtures. Use only WAGNER original spare parts and accessories.

The device may only be operated under the following conditions:

The operating personnel must be trained on the basis of this operating manual. The safety regulations listed in this operating manual must be observed. The operating, maintenance and repair information in this operating manual must be

observed. The statutory requirements and accident prevention regulation standards in the country

of use must be observed.

The powder center may only be used if all parameters are set and all measurements/safety checks are carried out correctly.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

2.5 PROCESSIBLE WORKING MATERIALS

Electrostatically charged powder types Metallic powder

2.6 REASONABLY FORESEEABLE MISUSE

Use of damp powder lacquer Working with liquid coating products Use of defective components and accessories Use for foodstu s

PXM

2.7 RESIDUAL RISKS

Residual risks are risks which cannot be ruled out even in the event of correct use. If necessary, warning and prohibition signs at the relevant points of risk indicate residual risks.

Residual risk Source Consequences Speci c measures Lifecycle phase

Skin contact with powder lacquers and cleaning agents

Powder lacquer in air outside the de ned working area

Noise Exhaust system Hearing damage Wear ear protection Operation

Handling powder lacquers and cleaning agents

Lacquering outside the de ned working area

Blowing-out system Cleaning

Skin irritations, Wear protective

clothing

allergies Observe safety data

sheets

Inhalation of substances hazardous to health

Observe work and operation instructions

Operation,

maintenance, disassembly Operation, maintenance

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

3 IDENTIFICATION

3.1 EXPLOSION PROTECTION IDENTIFICATION

The PXM powder center is intended for construction outside of the dust Ex-zone (Zone 22).

3.2 PERMISSIBLE DEVICE COMBINATIONS

The following components may be used in the PXM powder center:

PI-F1 injector Hi-Coat ED injector Ultrasonic screening device (version for PXM with replaceable  lter) IP 5000 powder pump EPG S2 control unit EPG-Sprint X control unit MCC controller MCS 1 controller CPD 1

PXM

3.3 TYPE PLATE

Powder center Control cabinet

P_02628

P_02627

Note:

The type plate may only be attached with the CE mark if the complete installation (powder center, controller, add-on parts, etc.) complies with the provisions of the EC directives.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

3.4 NOTE ON THE EXZONE CLASSIFICATION BY THE OPERATOR

Decreased intrinsic emission is used by the PXM powder center to create a reduced zone extension as compared to classi cation and presentation as per EN 12981 (version 2010/06)* and BGI 764 (version 2009/10, as per 2014/02)*. The permanent openings are facilitated. It is ensured by design and construction. Therefore, operation is permitted only upon compliance with all the following requirements:

– The minimum air extraction rate corresponds to the operating manual and is ensured – The powder center can only be operated when technical ventilation equipment is

active (interlock with exhaust air) – The open box is not  uidized, the  uidized box is only operated with "cover for box" – The  uidized tank is closed with "cover for  uidized tank" – The powder hoses and connections are airtight – Necessary cleaning times are kept short – The notes in the operating manual on safe operation are being observed.

PXM

Compliance with all the requirements and measures results in no relevant powder discharge. The zone extension caused by the powder center can be seen in the following images:

P_02590

Zone 20 in the tank and in the sieve chamber of the ultrasonic sieve Zone 22 within the powder center No zone caused by the powder center

* The EU standard and BG information are being revised. The exemptions shall be taken

into account in future versions.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

4 GENERAL SAFETY INSTRUCTIONS

4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR

Keep this operating manual on hand near the device at all times. Always follow local regulations concerning occupational safety and accident prevention.

4.1.1 ELECTRICAL DEVICES AND EQUIPMENT

To be provided in accordance with the local safety requirements with regard to the

operating mode and ambient in uences.

May only be maintained by skilled electricians. Must be operated in accordance with the safety regulations and electrotechnical

regulations.

Must be repaired immediately in the event of problems. Must be decommissioned if they pose a hazard. Must be de-energized before work is commenced on active parts. Secure the device against being switched back on without authorization. Inform sta

about planned work.

Observe electrical safety regulations.

PXM

4.1.2 PERSONNEL QUALIFICATIONS

Ensure that the device is only operated, maintained and repaired by trained persons.

4.1.3 SAFE WORK ENVIRONMENT

The  oor in the working area must be electrostatically conductive (measurements

according to EN 1081).

Make sure that all persons within the working area are wearing electrostatic-conductive

shoes.

Ensure that gloves worn are made of conductive material. The powder release must be electrically interlocked with the powder spray system's

exhaust air equipment.

Excess coating product (overspray) must be collected up safely. Ensure that there are no ignition sources such as naked  ames, sparks, glowing wires,

or hot surfaces in the vicinity. Do not smoke.

Maintain su cient quantities of suitable  re extinguishers and ensure that they are

serviceable.

The operating company must ensure that an average concentration of powder lacquer

in the air does not exceed 50% of the lower explosion limit (LEL = max. permitted

concentration of powder to air). If no reliable LEL value is available, the average

concentration must not exceed 10 g/m³.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

4.2 SAFETY INSTRUCTIONS FOR STAFF

Always follow the information in this manual, particularly the general safety instructions

and the warning instructions.

Always follow local regulations concerning occupational safety and accident

prevention.

Under no circumstances may people with pacemakers enter the area where the

high-voltage  eld between the spray gun and the work piece to be coated builds up!

4.2.1 SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES

Do not point spray guns at people. Before all work on the device, in the event of work interruptions and functional faults:

- Switch o the energy/compressed air supply.

- Secure the spray gun against actuation.

- Relieve pressure on spray gun and device.

- In case of functional faults: Identify and correct the problem, proceed as described in the "Fault Recti cation" chapter.

PXM

4.2.2 GROUNDING THE DEVICE

The electrostatic charge may, in certain cases, give rise to electrostatic charges on the device. This may result in the formation of sparks or  ames when discharging.

Ensure that the device is grounded before each coating process. Ground the work pieces to be coated. Make sure that all persons inside the working area are grounded, e.g., that they are

wearing electrostatically conductive shoes.

The functionality of grounding cables must be checked regularly (see EN 60204).

4.2.3 PRODUCT HOSES

Only use an original WAGNER powder hose.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

4.2.4 CLEANING

Before starting cleaning or any other manual work, the high-voltage in the spray area

must be shut down and locked to prevent it from being switched back on. Lock the compressed air supply and decompress the device. Secure the device against being switched back on without authorization. Use only electrically conducting and grounded tanks for cleaning  uids. Preference should be given to non- ammable cleaning  uids. Flammable cleaning liquids may only be used if, after switching o the high-voltage,

all high-voltage conducting parts are discharged to a discharge energy of less than

0.24 mJ before they can be accessed.

Most  ammable solvents have an ignition energy of around 0.24 mJ or 60 nC.

The cleaning agent's  ash point must be at least 15 K above the ambient temperature. Only mobile industrial vacuum cleaners of design 1 (see EN 60335-2) may be used to

remove dust deposits.

PXM

4.2.5 HANDLING POWDER LACQUERS

When preparing or processing the powder and cleaning the device, take note of the

processing regulations laid down by the manufacturer of the powder lacquers being

used. Take note of the manufacturer’s instructions and the relevant environmental protection

regulations when disposing of powder lacquers. Implement the prescribed safety measures, in particular the wearing of safety glasses

and safety clothing as well as the use of protective hand cream. Use a mask or breathing apparatus if necessary. To ensure su cient protection of health and the environment, only operate the device

in a powder booth or on a spray wall with activated ventilation (exhaust air).

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

5 DESCRIPTION

5.1 COMPONENTS

PXM

P_02520

6789

1 Rack for EPG control units 2 Warning lamp with built-in alarm horn 3 Control cabinet with operating elements 4 Reciprocator with powder injectors and intake systems 5 Level sensor 6 Holder for box or container 7 Cleaning station for reclaimed powder; park station for loss mode of operation 8 Fresh powder supply 9 Cleaning position for fresh powder lance

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

5.1.1 VERSION WITH INTEGRATED FILTER

PXM

P_02521

10 Filter suction 11 Fresh powder pump 12 Pressure switch for monitoring the mains pressure 13 Adapter for  lter suction

Alternatively: Adapter to connect to the  nal  lter

14 Powder catch basin

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

5.1.2 VERSION FOR FINAL FILTER

PXM

P_02674

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

5.1.2 VERSION WITH ULTRASONIC SIEVE

PXM

P_02675

1 Sieve frame with converter 2 Sieve housing 3 Powder spout

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

5.2 MODE OF OPERATION

The PXM powder center is a system from which  uidized powder is conveyed simultaneously from a powder tank (option) to several spray guns. Powder consumption is compensated by the fresh powder feed device (option) in the powder center or by manually re lling.

The linear motion unit suction system is immersed directly into the powder tank. A homogenous powder/air mixture is created through the  uidization and vibration (option) of the tank. The injectors convey the powdered paint to the guns in the coating system. A lowered powder level in the tank is detected by the level sensor in conjunction with sensors on the reciprocator. The level sensor also triggers the lowering of the suction system and the fresh powder supply (option) when necessary. A warning is triggered automatically in the event of a powder shortage and the warning lamp lights up yellow. If the minimum level is not reached after a certain time, the alarm lights up red and the system registers a malfunction. Powder level monitoring is active only in automatic mode.

PXM

5.3 PROTECTIVE AND MONITORING EQUIPMENT

Protective and monitoring equipment must not be removed, modi ed or rendered

unusable.

Regularly check for perfect functioning. If defects are detected on protective and monitoring equipment, the system must not

be operated until these defects are remedied.

Safety Device E ect

EMERGENCY STOP button – Powder feed blocked

– Linear motion unit blocked – Fluidization and vibrator deactivated

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

5.4 SCOPE OF DELIVERY

Quantity Order No. Designation

1 see Chapter 5.4.1 PXM powder center

The standard equipment includes:

1 Declaration of incorporation 1 2350371 Operating and assembly manual, German 1 see Chapter 1.3 Operating and assembly manual in the local language

5.4.1 DESIGN VARIANTS OF THE PXM POWDER CENTER

Basic Module:

Order No. Designation

2350977 Powder center PXM 20/22 IF standalone, without ultrasonic sieve 2350980 Powder center PXM 20/22 FF standalone, without ultrasonic sieve 2359437 Powder center PXM 34 IF standalone, without ultrasonic sieve

Powder center PXM 34 FF standalone, without ultrasonic sieve

PXM

Expansion Modules*:

Order No. Designation

2350981 Injector set PI-F1 2350982 Injector set HiCoat-ED 2350983 Set EPG S2 2350984 EPG rack 1–11 for PXM 20/22 2359443 EPG rack 1–18 for PXM 34 2350987 Vibration table container/box 2350988 Box  uidizing device (only possible for PXM 20/22) 2350990 Box fresh powder addition 2341584 External valve cabinet for single-plug conveyor 2353462 Extension set ultrasonic sieve device 160 μm 2353306 Extension set ultrasonic sieve device 200 μm 2353302 Controller extension bigbag (without bigbag) 2350985 Set connection material for injectors and EPG including installation

* Expansion modules can be used only in conjunction with an order of the basic module.

Product-speci c limitations, e.g.,  ow rates must be observed and taken into account during the con guration.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

5.4.2 TYPE WITH ULTRASONIC SCREENING UNIT

P_02370

PXM

For more information on the ultrasonic screening unit, see operating manual for ultrasonic screening unit.

5.4.3 INSTALLATION DIMENSIONS FOR ULTRASONIC SCREENING UNIT

678520

P_02561

450

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

5.5 TECHNICAL DATA

Dimensions:

Maximum height 2,660 mm; 104.72 inches Maximum width 2,170 mm; 85.43 inches Maximum depth 1,400 mm; 55.12 inches Weight Approx. 500 kg + 150 kg  lter suction

Electrical:

Three-phase current connection 230/400 V 3P/N/PE 50 Hz Frequency 50 Hz Total power consumption 1.5 kW (without  lter)/3.7 kW (with  lter) Protection class IP 54

Pneumatic:

Compressed air connection 0.6 – 0.8 MPa; 6 – 8 bar; 87 – 116 psi Cross-section of compressed air line At least 1.5" Compressed air quality 6.5.2 according to ISO 8573.1: 2010 Air throughput coating mode 45 Nm³/h; 1,588.88 cf/h Air throughput cleaning mode 100 – 150 Nm/h in approx. 30 sec. Suction capacity, exhaust 4,000 m³ at 1,300 Pa; 5,230.86 cubic yards at 0.19psi Filter surface area (version with  lter) 40 m²; 430.55 square foot Number of  lters 2 Filter capacity > 99% Permanent suction output for version with connection to a  nal  lter: 1,000 Nm/h; 35,308.34 cf

Equipment:

PXM

WARNING

Exhaust air containing oil!

Risk of poisoning if inhaled.

Provide compressed air free from oil and water

(Quality Standard 7.5.4 as per ISO 8573.1, 2010)

7.5.4 = 5-10mg/m³ / ≤7 °C; 44.6 °F / 5 mg/m³.

Number of injectors PXM 20/22: 20 injectors when feeding from the box

PXM 20/22: 22 injectors when feeding from the  uid tank PXM 34: 34 injectors when feeding from the  uid tank

Ambient conditions:

Operating temperature range 5 – 45 °C; 41 – 113 °F

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

5.6 CONTROLS

PXM

P_02522

1 Touch screen for operating the PXM 2 Fault display: Lights up red when the emergency stop chain is interrupted

Button to reset the EMERGENCY STOP safety relay 3 EMERGENCY STOP switch 4 Safety button for two-hand control function 5 Pressure gauge for  uid air 6 Fluid air regulator

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

5.7 SCREEN LAYOUT OF THE TOUCH SCREEN

Information bar

Service

PXM

Function graphic

Function bar 1

P_02591

P_02592

Manual

Auto

Home page

Cleaning

Menu bar

Settings

Alarm

Released functions and components are marked by a yellow frame.

Activated functions and components are depicted by yellow highlighted icons or buttons.

Non-activatable functions are depicted by a gray font for each function button and a gray frame.

Settings

P_02593

Tap on the respective component/function on the touch screen to switch things on and o .

The status of the individual components is depicted on the screen by di erent colors of the points on the respective components:

Status Display Description

Gray Not active Green Ready Flashes yellow Warning Lights up yellow During fresh powder feed in automatic mode:

The fresh powder conveyor is ready to feed powder, but enough powder is available

Flashes red Malfunction

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

5.8 EXPLANATION OF THE SCREEN PAGE NUMBERS

The screen pages are numbered from top to bottom (1-4) in the menu bar and from left to right (1-5) in the function bar.

3 - 2 - 3

Button number in function bar 2 Button number in function bar 1 Button number in the menu bar

PXM

Page number

Service

RP supply

Operating mode

RP feed time [sec]

RP break time [sec]

Message recovery system [sec]

Work station

Settings System

supply

operation

No Yes

Duration Eco

Standard

supply

cleaning

Exhaust

system

Diagnosis

SAT

Function bar 1

Function bar 2

"Scroll forwards/backwards" buttons

Home page

Cleaning

Settings

Alarm

Menu bar

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

5.9 INPUTS ON THE TOUCH PANEL

Pulse time [sec]

Exhaust system

PXM

Home page

Filter cleaning

Work station

Settings System

operation

cleaning

Diagnosis

Cleaning

Settings

Alarm

To modify number values, touch the value that is to be modi ed and the keypad shown above appears.

The minimum and maximum setting values are displayed on the right; lower or higher values are not applied.

Button assignment:

BACK Cancel: the entered value is not applied. EXIT The input  eld is left without applying the set value. ENTER The entered value is applied.

5.10 DISPLAYS ON THE WARNING LAMP

Illuminated Display Description

Green

Flashes red brie y Warning Flashes red at regular intervals Malfunction Blue Cleaning is active Alarm horn sounds Malfunction

Powder center ok ➔ No malfunction – Exhaust air OK – Ventilator is running

VERSION 08/2015 ORDER NUMBER DOC2350372

PXM

OPERATING AND ASSEMBLY MANUAL

5.11 USER RIGHTS

Main menu Sub-menu Function Worker Supervisor Service Facility

Home page x x x x Cleaning x x x x Settings Settings Workstation x x x x

Powder supply x x x x US Sieve x x x x Test x

MP operation Workstation x x x

FP supply x x x RP supply x x x Exhaust system x x x US Sieve x x x Hardware x x x

MP cleaning Interface x x x

Injectors x x x FP supply x x x RP supply x x x US Sieve x x x

Diagnosis LogView x x

Diagnosis x x Maintenance x x

System Password x x x

Data backup x x x Backup x x x IP setting x x Exit visualization

software

Alarm Current View x x x x

Con rm x x x x

History View x x x x

Save as *.csv x x x Save as *.xml x x x Delete x

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

6 ASSEMBLY AND COMMISSIONING

6.1 TRAINING THE ASSEMBLY STAFF

WARNING

Incorrect installation/operation!

Risk of injury and damage to the device.

The assembly and commissioning sta must have the technical

skills to safely commission the device.

When assembling, commissioning and performing all work,

please read and observe the operating manual and safety regulations of the additionally required system components.

PXM

A skilled person must check to ensure that the device is in a reliable state after it is installed and commissioned.

6.2 STORAGE CONDITIONS

Until the point of assembly, the powder center must be stored in a dry location, free from vibrations and with a minimum of dust. The powder center must be stored in closed rooms. The air temperature at the storage location must be between +10 °C and +20 °C (+50 °F and +68 °F). The relative air humidity at the storage location must be between 20 and 70% (without condensation).

6.3 INSTALLATION CONDITIONS

The air temperature at the installation site must lie between +10 °C and +30 °C (+50 °F and +86 °F). The relative air humidity at the installation site must be between 20 and 70% (without condensation).

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

6.4 TRANSPORTATION

WARNING

Parts have high weights and centers of gravity!

Risk of injury and damage to the device.

Only use appropriate lifting tackle (crane, fork lift) for assembly. Secure the parts against tipping during transport. Cordon o assembly area to keep out unauthorized persons.

The powder center is delivered completely mounted to the site of installation. This may be supplied separately for a version with its own  lter suction. Final assembly is performed on-site.

PXM

Transportation and warehouse operations may only be performed by quali ed personnel, especially in the use of industrial trucks, ladders and cranes.

The selected means of transport must be suitable and permissible for the respective component weights.

For the insertion of parts at the installation site, an opening width of at least 2,000 mm (6.56 ft.) must exist, and an opening height of 2,000 mm (6.56 ft.). The PXM powder center is delivered upright.

P_02571

Support with wooden beams on the truck Loading/unloading with forklift

P_02572

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

PXM

P_02573

Transport in the factory workshop Support with wooden beams on the

P_02574

 lter module

6.5 ASSEMBLY AND INSTALLATION

WARNING

Danger from electric current!

Risk of injury and damage to the device.

Before connecting the device, ensure that the external controller

is switched o and the EMERGENCY STOP button is actuated.

The device may only be put into operation if it complies with the essential requirements of Directive 2006/42/EC after installation.

The requirements of the relevant paragraphs must be met in particular: – 1.1.4 Illumination – 1.2.4.1 Normal shutdown – 1.2.4.3 Emergency shutdown – 1.2.4.4 Assemblies of machinery – 1.2.5 Selecting the control or operating modes – 1.2.6 Power supply malfunction – 1.3.7 Risks from moving parts – 1.3.8 Selection of protective equipment against risks from moving parts – 1.5.6 Fire – 1.5.16 Lightning – 1.7.1.2 Warning devices

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

P_02575

PXM

1. Fasten  lter module (if available) to the powder center housing. It is fastened with 12 screws from the back; two screws must have contact disks for

proper grounding.

P_02576

2. Connect the compressed air supply to the air connection point (air connection point1"; supply at least 1.5"; pressure regulator setting 6 bar).

3. Introduce the electrical cables from the top or from the back and connect these to the main terminal.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

PXM

P_02577

P_02578

4. Erect the piston cylinder and guide the piston through the roof. The limit switches must be located on the left side (seen from the front).

5. Use 4 screws to fasten piston cylinder onto the roof.

Workstation

Position switch of linear motion unit

Powder level sensor

LogView Diagnosis Maintenance

Settings System

operation

at the top

Warning

Minimum

Cleaning

cleaning

Diagnosis

Home page

Cleaning

Settings

Alarm

6. Connect the compressed air and power supply.

7. Move the cylinder downwards via the touch screen (diagnostic page) and screw into place.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

P_02581

8. Align the  ange by hand and use 3 screws to fasten onto the injector retaining plate.

PXM

Workstation Position switch of linear motion

unit

Powder level sensor

LogView Diagnosis Maintenance

Settings System

operation

at the top Warning Minimum Cleaning

cleaning

Diagnosis

Home page

Cleaning

Settings

Alarm

9. Move the piston cylinder via the diagnostic side to adjust the limit switches.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

P_02622

PXM

Limit switch 1: Top = Cylinder moved all the way up.

Setting: Uppermost cylinder position

Limit switch 2: Warning = Advance warning that the powder level will be reached soon.

Setting: 2 cm above limit switch 3

Limit switch 3: Minimum = Powder level minimum; cylinder does not move further

downwards. Setting: Fluid tubes 1 cm from the  uid  oor of the tank; use tank

Order No. 3304505.

Limit switch 4: Cleaning = Intake tubes dip into blowout nozzles.

Setting: Intake tube 1 cm in blowout nozzle

P_02583

10. Horizontally align the PXM using the leveling feet on the frame.

11. Align the intake tubes so that they meet centrally in the blowout nozzles.

To do this,  rst align the PXM with the leveling feet. If necessary, loosen the four screws from the mounting plate of the blowout nozzles

and bring the nozzles into position.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

6.6 GROUNDING

For safety reasons the system must be properly grounded. WAGNER recommends the use of a copper cable of at least 16 mm² with su cient mechanical resistance for connection to the signal ground.

Good grounding of the work piece is also necessary for optimum powder coating.

A poorly grounded work piece causes:

dangerous electric charging of the work piece, very poor wrap-around, uneven coating, back spraying to the gun, i.e., contamination

Prerequisites for perfect grounding and coating are:

Conducting suspension for the work piece that is to be coated. Grounding of the powder coating booth, transport and suspension equipment to

be provided on site in accordance with the corresponding operating manuals or the de nitions laid down by the manufacturer.

Regular cleaning of hangers from powder residues. Grounding resistance for the work piece of a maximum of 1 MΩ (megaohm). Grounding cable connected to the controller module or control cabinet.

PXM

Sparks between work piece and conveyor hooks (hangers) can occur if hooks or other hanger parts are not completely cleaned! These sparks can cause heavy radio frequency interference.

6.7 SAFETY CHECKS

Perform safety checks in accordance with Chapter 8.2.3.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

6.8 COMMISSIONING

The tank mounting and injector mounting plate must be horizontally aligned in all directions.

The hose for the  uid air must either be connected to the terminal for the box- uidizing device ( oor) or on the powder tank.

PXM

P_02589

NOTICE

Positioning of powder tank and tank cover!

Danger of damage to the device.

Align the powder tank or powder box on the vibrator table so that the suction system

can move in and out unimpeded.

Only insert the cover into the guides and push it back to the limit stop after lowering

the suction tubes.

Remove cover before powering up the intake tubes.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

6.9 STANDARD SETTINGS

The most important settings for speedy commissioning of the powder center have already been carried out by the manufacturer. You can, however, change standard settings to suit your needs. The changes remain saved even if the powder center is switched o with the main switch.

The following standard settings are made in the factory.

6.9.1 MACHINE PARAMETERS OPERATION

Workstation

Alarm delay powder shortage: 30 sec.

FP supply

FP station: 1 FP bigbag: 1 Bigbag type: IP 5000 FP redosing time manual: 30 sec. FP redosing time automatic: 30 sec.

RP supply

RP supply: Yes Operating mode: Eco RP feed time: 50 sec. RP break time: 10 sec. Message recovery system: 60 sec. RP supply: Cycle 1: 2.5 sec.

Cycle 2: 0.3 sec. Cycle 3: 2.5 sec. Cycle 4: 0.3 sec.

US sieve

US sieve: No After-run time if US sieve available: 30 sec. Dirt discharge: 3 pulses After-run time before: 12 sec. Wait time: 10 min. Pulse time: 1.0 sec. Break time: 5.0 sec.

Exhaust system

Exhaust system: Integrated Filter cleaning pulse time: 0.2 sec. Filter cleaning break time: 60 sec. Final  lter, automatic closing: 10 sec.

PXM

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

6.9.2 MACHINE PARAMETER CLEANING

Interface

Communication with the application controller: No

Injectors

Preliminary cleaning Block 1 Number of pulses: 2 Pulse time: 0.2 secs Break time: 1 secs Preliminary cleaning Block 2 Number of pulses: 2 Pulse time: 0.2 secs Break time: 1 secs Cleaning Block 1 Number of pulses: 8 Pulse time: 0.5 secs Break time: 2 secs Cleaning Block 2 Number of pulses: 8 Pulse time: 0.5 secs Break time: 2 secs Dynamics: O

FP supply

Pre-cleaning Number of pulses: 2 Pulse time: 0.5 secs Break time: 2.0 secs Cleaning Pulse time: 1.0 secs Break time: 2.0 secs

RP supply

Cleaning Number of pulses: 10 Pulse time: 1.0 secs Break time: 2.0 secs

US sieve

Pre-cleaning Number of pulses: 5 Pulse time: 0.2 secs Break time: 2.0 secs Cleaning Number of pulses: 5 Pulse time: 0.5 secs Break time: 2.0 secs

PXM

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

6.9.3 CAN ADDRESSES FOR MCM SYSTEM

CAN Node Module Type Application

0 CAN Diagnosis Do not use 1 CAN Open Master 1 MCM CAN 1 2 CAN Open Master 2 MCM CAN 2 3 I/O Module MCM CPS

11 HU1 No. 1 Sliding table 1 12 HU1 No. 2 Sliding table 2 13 HU1 No. 3 Sliding table 3 14 HU1 No. 4 Sliding table 4

21 VU1 No. 1 Reciprocator 1 22 VU1 No. 2 Reciprocator 2 23 VU1 No. 3 Reciprocator 3 24 VU1 No. 4 Reciprocator 4

PXM

31 EPG S2 No. 1 Guns 1 and 2 32 EPG S2 No. 2 Guns 3 and 4 33 EPG S2 No. 3 Guns 5 and 6 34 EPG S2 No. 4 Guns 7 and 8 35 EPG S2 No. 5 Guns 9 and 10 36 EPG S2 No. 6 Guns 11 and 12 37 EPG S2 No. 7 Guns 13 and 14 38 EPG S2 No. 8 Guns 15 and 16 39 EPG S2 No. 9 Guns 17 and 18 40 EPG S2 No. 10 Guns 19 and 20 41 EPG S2 No. 11 Guns 21 and 22 42 EPG S2 No. 12 Guns 23 and 24 43 EPG S2 No. 13 Guns 25 and 26 44 EPG S2 No. 14 Guns 27 and 28 45 EPG S2 No. 15 Guns 29 and 30 46 EPG S2 No. 16 Guns 31 and 32

61 Light curtain portal Kontur 2, with Quattro CAN Open 62 CML 720 light curtain CML 720i height light curtain 63 CML 720 light curtain CML 720i depth light curtain, right 64 CML 720 light curtain CML 720i depth light curtain, left 65 CML 720 light curtain CML 720i code catching

81 Extension module for recipe selection (11 bit)

82 … 127 not de ned free application

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

6.9.4 EPG S2 SETTINGS

Normally, these settings have been made prior to shipment. The description is for reference purposes only and when an error message is displayed.

PXM

Mains power IN / OUT

Netz EIn / Ausgang

P_02714

Prim. Fuse

Sicherung

1.0 AT

(slow blow)

Feeding air

Förderluft

Air input

Lufteingang

Dosage air

Dosierluft

Made in Switzerland

J. Wagner AG CH 9450 Altstätten

0102

Type / Typ:

EPG S2 FM

Voltage:

90-250 VAC 47-63 Hz

Spannung:

Line Power:

Eingangsleistung:

FM approved for CL II, Div 2 Grps E, F, & G

Ambient temp range 5C to 45C T5 Use in accordance with

control document:

Serial No.:

Serie Nr.:

max. 65 W

2309729

Do NOT connect or disconnect when ENERGIZED !

Controller is suitable for Class II, Division 2, Hazardous (Classified) locations.

For operation all ports must be fitted with a plug or the protection cap.

Overvoltage Category II and pollution Degree 2

IN CAN Bus OUT Data and Interlock

Daten und Verriegelung

Spraygun

Sprühpistole

Output to gun

Ausgang zur Pistole

U max. 22 Vpp I max. 0,9 A

AABB

Atomizing air

Zerstäuberluft

Feeding air

Förderluft

Dosage air

Dosierluft

Atomizing air

Zerstäuberluft

CAN bus node ID setting

CAN bus baud rate setting/emergency operation mode

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

Switch CAN baud rate Maximum

1234 0 0 0 X 1,000 kBit/s 25 m

1 2 3 4

Baud rate

P_01509

Shown example: Factory setting 250 kBit/s

Setting address of each EPG S2, starting from 31 for the  rst EPG S2 (from top to bottom)

0 0 1 X 800 kBit/s 50 m

0 1 0 X 500 kBit/s 100 m 0 1 1 X 250 kBit/s 250 m 1 0 0 X 125 kBit/s 500 m 1 0 1 X 100 kBit/s 1,000 m 1 1 0 X 50 kBit/s 1,000 m 1 1 1 X 20 kBit/s 1,000 m

cable length

PXM

CAN Node Module Type Application

Node ID 01 (0/1)

P_02715

Node ID 23 (2/3)

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

6.10 FUNCTION TEST

The function test is performed after the system has been con gured.

Test all the functions on the touch screen in manual mode Test the cleaning process Test  uidization Test fresh powder pump Test automatic operation

PXM

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

PXM

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

7 OPERATION

7.1 TRAINING THE OPERATING STAFF

WARNING

Incorrect operation!

Risk of injury and damage to the device.

The operating sta must be quali ed to operate the entire system. The operating sta must be familiar with the potential risks

associated with improper behavior as well as the necessary protective devices and measures.

Before work commences, the operating sta must receive

appropriate system training.

PXM

7.2 SAFETY INSTRUCTIONS

Observe safety instructions in Chapter 4.

WARNING

Incorrect operation!

Risk of injury and damage to the device.

Take appropriate precautionary measures, e.g. wear protective

clothing, if contact with powder products or cleaning agents causes skin irritation.

The footwear worn by operating sta must comply with

EN ISO 20344. The measured insulation resistance must not exceed 100 megohms.

The protective clothing, including gloves, must comply with

EN ISO 1149-5. The measured insulation resistance must not exceed 100 megohms.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

7.3 TOUCH SCREEN OPERATION STANDARD EQUIPMENT

7.3.1 EQUIPMENT WITH FINAL FILTER

PXM

1 4 5 6

13 10

Manual

Auto

891112

Home page

Cleaning

Settings

Alarm

P_02524

1 Peristaltic pump On/O 2 Exhaust system status 3 Ultrasonic sieve device On/O 4 Language selection 5 Reciprocator Up/Down 6 Manual/automatic mode 7 Illumination On/O 8 Button for clamping the tank (box, powder container)*

9 Replenishing fresh powder (manual, time-controlled) On/O 10 Workstation/vibrator  uidization On/O 11 Automatic fresh powder supply On/O (only in automatic mode) 12 Throttle valve Open/Closed 13 BigBag fresh powder On/O , as an alternative to the fresh powder supply from the box

* Additional actuation of the safety switch for two-handed operation below the touch

screen required

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

7.3.2 EQUIPMENT WITH INTEGRATED EXHAUST SYSTEM

PXM

1 4 5 6

1 Peristaltic pump On/O

2 Exhaust system status

3 Ultrasonic sieve device On/O

4 Language selection

5 Reciprocator Up/Down

6 Manual/automatic mode

7 Illumination On/O

8 Button for clamping the tank (box, powder container)*

9 Replenishing fresh powder (manual, time-controlled) On/O 10 Workstation/vibrator  uidization On/O 11 Automatic  lter cleaning On/O 12 Automatic fresh powder supply On/O (only in automatic mode) 13 Exhaust system On/O // Switchover frequency

Press the button brie y: Switch on suction Press the button brie y when suction is switched on: Switchover frequency ventilator Press and hold the button: Switch o suction

14 Bigbag fresh powder On/O , as an alternative to the fresh powder supply from the

box

P_02529

8912

1114 13

* Additional actuation of the safety switch for two-handed operation below the touch

screen required

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

7.4 SET LANGUAGE

Language

PXM

1. Tap "Flag" button in the information bar.

The depicted screen appears.

2. Select the desired language by tapping on the corresponding  ag button.

The screen is now displayed in the selected language.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

7.5 LOGGING A USER ON/OFF

The currently logged in user is displayed in the information bar, in the example "Factory". Press the button to change the user; the following display appears.

Factory

Set authorization

Log on user Log o user

PXM

Press the "Log in user" button; the following display appears.

Factory

Password

Enter the password for the desired user level and press the "Enter" button. It is switched to the desired user level. Press the "Log off user" button to go back to the lowest level (operator level).

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

7.6 STARTING/STOPPING COATING

1. Switch the system on.

2. Move the reciprocator all the way to the top (reference).

3. Set the powder tank. For boxes, loosen powder beforehand.

4. When feeding from the powder box: Pull the foil over the box rim until it lies  at on the box walls.

5. Insert  uidization and check pressure (start with 0.5 bar setting).

6. Plug the peristaltic pump tube and fresh powder hose onto the loss position.

7. Select the "Automatic" button; the retractor then moves downwards and determines the powder level.

When using boxes, ensure that the  uid device moves past the foil and does not press it down.

If necessary, retighten the foil.

8. Check  uidization and set if necessary. When using a  uid tank, the powder should  ow like water without generating

larger bubbles. When using powder boxes, the powder should be  owable in the  uid rod area

without generating larger bubbles or dust. Note: An excessive  uid air setting leads to a greater loss of powder.

9. Insert tank cover.

10. Plug the fresh powder hose*

11. Start coating.

12. First switch o the peristaltic pump on the touch screen according to an arbitrary time, plug the hose *

13. For longer breaks and at the end of production, switch to manual mode and move the suction system from the tank to the top in reverse order.

Attention: Remove the cover  rst.

14. At the end of production, WAGNER recommends you rough clean the system and  ush the injectors, powder hoses and guns (via application controller) and perform a normal cleaning for the IP 5000 fresh powder pump.

Move the suction device completely up before turning o the system. Remove tank or box or close with a dummy cover so that no debris can fall into it. Note: If the PXM is connected to the  nal  lter, the throttle valves can only be opened

if no coating is applied.

, **

onto the tank cover.

on the tank cover and switch the peristaltic pump on again.

PXM

* When an automatic fresh powder supply is available

** When using an ultrasonic sieve, plug the fresh powder hose directly onto the

connection on the sieve and the peristaltic pump tube on the feedthrough socket on the base plate of the powder center

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

7.6.1 PAINT CHANGE COMPONENTS

PXM

P_02676

12345

1 Blowout nozzles for intake tubes 2 Blowout nozzle for the fresh powder hose and peristaltic pump tube 3 Parking station peristaltic pump tube during loss operation 4 Parking station, fresh powder hose 5 Cleaning position, fresh powder lance

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

7.6.2 CLEANING POSITIONS POWDER HOSES

P_02679

P_02677

Cleaning fresh powder, standard

Loss position, reclaimed powder

PXM

P_02678

Cleaning fresh powder, intensive

P_02680

Cleaning, reclaimed powder

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

7.7 CONFIGURING THE POWDER CENTER

The con guration of the powder center must be adjusted when  rst commissioning or in special cases. Con guration is performed in the "Settings" menu item. Different configuration settings are displayed depending on the user level selected.

Icon explanation:

Button for scrolling to the next screen page

Button for scrolling back to the previous screen page

PXM

P_02621

Number of pulses

Pulse time (duration)

Break time (duration)

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

7.7.1 SETTINGS

The settings can be temporarily changed and adapted to the speci c work situation.

The maximum con guration is displayed below, i.e. the switches become visible depending on the con guration.

Meaning of a deselection:

- Icon is nevertheless displayed on the home page (gray)

- Fresh powder feed cannot be switched on (manual mode)

- Deselected components do not work in automatic mode

Workstation

Home page

PXM

Vibrator

Work-

station

Settings

Powder

supply

operation

Yes No

US sieve

cleaning

Diagnosis

System

Cleaning

Settings

Alarm

Parameter: Explanation:

Vibrator Yes: Vibrator available at the workstation

No: No vibrator available at the workstation

Fresh powder supply

Home page

Internal

FP 1

Bigbag 1External Bigbag 2

Cleaning

Work-

station

Settings

Powder

supply

operation

US sieve

cleaning

Diagnosis

System

Settings

Alarm

Parameter: Explanation:

FP 1 Fresh powder pump 1 is active (selected)

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

7.7.2 MACHINE PARAMETERS OPERATION

The settings in the "Operation" machine parameters are normally not changed since they are defined by the installed hardware.

PXM

Fault trigger delay powder shortage

WS cylinder lowering Feeding rate [sec]

WS cylinder lowering Break time [sec]

Time setting for level controller [sec]

Work-

station

Settings System

supply

operation

supply

cleaning

Parameter: Explanation:

Fault trigger delay powder shortage

WS cylinder lowering Feeding rate [sec]

WS cylinder lowering Break time [sec]

Time setting for level controller [sec]

Delay time after which an error message is triggered in the case of powder shortage

Period of time in which the workstation cylinder is supplied with compressed air during raising and lowering

Period of time in which the workstation cylinder is not supplied with compressed air during raising and lowering

Delay time after which the linear motion unit lowered during a powder shortage and the fresh powder pump is switched on

Exhaust

system

Diagnosis

Standard

Home page

Cleaning

Settings

Alarm

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

PXM

FP station

FP bigbag

Bigbag type

FP redosing time man. [sec]

FP redosing time auto [sec]

Work-

station

Settings System

supply

operation

supply

cleaning

Standard

Exhaust

system

Diagnosis

Home page

Cleaning

Settings

Alarm

Parameter: Explanation:

FP station No: No fresh powder pump available

1: A fresh powder pump is available (installed) 2: Two fresh powder pumps are available (installed)

FP Bigbag No: No fresh powder pump available on the bigbag

1: An external fresh powder pump is available (installed)

2: Two external fresh powder pumps are available (installed) Bigbag type FP redosing time man. [sec] Redosing time of the fresh powder pump in manual mode FP redosing time auto [sec] Redosing time of the fresh powder pump in automatic mode

If the "FP bigbag" parameter is set to 1 or 2, then the "Bigbag type" parameter is displayed.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

PXM

RP supply

Operating mode

Message recovery system [sec]

Work-

station

Settings System

supply

operation

Yes

Duration

supply

cleaning

Eco

Standard

Exhaust

system

Diagnosis

Home page

Cleaning

Settings

Alarm

Parameter: Explanation:

RP supply Yes: Reclaimed powder pump available

No: No reclaimed powder pump available SAT: Speci c con guration for the SAT system

Operating mode Duration: Peristaltic pump operates continuously

Eco: Peristaltic pump works per cycle, that is, it works during the "Feed time" adjustable time and subsequently switches off for the "Break time" adjustable time (power saving mode)

Message recovery system [sec] A timer runs at the speci ed time after the initial

feed after cleaning. After this time expires, a note is displayed on the screen to plug the recovery hose from the loss position to the recovery position.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

PXM

RP supply

Operating mode

RP feed time [sec]

RP break time [sec]

Message recovery system [sec]

Work-

station

supply

operation

Yes

Duration Eco

supply

cleaning

Standard

Exhaust

system

DiagnosisSettings System

Home page

Cleaning

Settings

Alarm

Parameter: Explanation:

RP supply Yes: Reclaimed powder pump available

No: No reclaimed powder pump available SAT: Speci c con guration for the SAT system

Operating mode Duration: Peristaltic pump operates continuously

Eco: Peristaltic pump works per cycle, that is, it works during the "Feed time" adjustable time and subsequently switches off for the "Break time" adjustable time (power

saving mode) RP feed time [sec] Period in which the reclaimed powder pump is running RP break time [sec] Time in which the reclaimed powder pump is at a standstill Message recovery system [sec] A timer runs at the speci ed time after the initial feed

after cleaning. After this time expires, a note is displayed

on the screen to plug the recovery hose from the loss

position to the recovery position.

Cycle 3

Exhaust

system

DiagnosisSettings System

Standard

Work-

station

Cycle 1 Cycle 4Cycle 2

supply

operation

cleaning

supply

Parameter: Explanation:

Cycle 1 – 4 Duration of the cycle 1 - 4

Home page

Cleaning

Settings

Alarm

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

PXM

Integrated

Standard

Exhaust

system

DiagnosisSettings System

Home page

Cleaning

Settings

Alarm

Automatic closing [sec]

Fault trigger delay ECO input [sec]

Work-

station

operation

supply

Final  lterExhaust system

supply

cleaning

Parameter: Explanation:

Exhaust system Final  lter: Final  lter available

Integrated: Filter module available

Automatic closing [sec] Time in which the throttle valves are automatically closed

after the time expires

Fault trigger delay ECO input [sec]

Integrated

Standard

Exhaust

system

DiagnosisSettings System

Home page

Cleaning

Settings

Alarm

Filter cleaning pulse time [sec]

Filter cleaning break time [sec]

Fault trigger delay ECO input [sec]

Work-

station

supply

operation

Final  lterExhaust system

supply

cleaning

Parameter: Explanation:

Exhaust system Final  lter: Final  lter available

Integrated: Filter module available Filter cleaning pulse time [sec] Duration of the cleaning pulses Filter cleaning break time [sec] Time in which no  lter cleaning takes place Fault trigger delay

ECO input [sec]

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

No StandardYesUS Sieve

PXM

After-run time [sec]

Dirt discharge:

After-run time before [sec]

Wait time [min]

US sieve Hardware

operation

cleaning

DiagnosisSettings System

Home page

Cleaning

Settings

Alarm

Parameter: Explanation:

US Sieve Yes: Ultrasonic screening device available

No: No ultrasonic screening device available

After-run time [sec] Sieve continues to run during each switch-o power

signal so that no residual powder remains on the fabric

(damage while blowing out!) Dirt discharge Number of suction cycles with pulse and break time After-run time before [sec] Before activating the dirt discharge, the screen

continues running in order to sieve remnants of

powder on the fabric (reduction of powder loss) Wait time [sec] Interval for debris discharge cycle

Home page

WAGO I/O assignment

Cleaning

US sieve Hardware

operation

cleaning

DiagnosisSettings System

Settings

Alarm

Parameter: Explanation:

WAGO I/O assignment This parameter is used to parameterize the various

con gurations of the powder center.

Each con guration has a di erent CAN node ID. 1: PXM without bigbag/node ID = 5 2: PXM with bigbag/node ID = 6 3: PXM with 34 injectors/node ID = 7

P_02716

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

7.7.3 MACHINE PARAMETER CLEANING

The settings in the "Cleaning" machine parameters can be optimized for customer-specific requirements.

Communication with the application controller

Home page

Yes

Cleaning

PXM

InjectorsInterface

Settings System

operation

supply

cleaning

Parameter: Explanation:

Communication with the application controller

Yes: The powder center controller communicates with the

application controller

In doing so, the following information is exchanged in

conjunction with MCC, Pro Tech M or S Pro Tech:

- Move the guns to the cleaning position for internal cleaning

- Switch on the gun air during internal cleaning

- Switch o the gun air after internal cleaning  nishes

No: The powder center controller does not communicate

with the application controller

CleaningPre-cleaning Dynamics

Block 2Block 1

Block 1

supply

Diagnosis

Block 2

US sieve

O

Settings

Alarm

Home page

Standard

Interface Injectors

operation

supply

cleaning

Standard

supply

DiagnosisSettings System

US sieve

Cleaning

Settings

Alarm

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

CleaningPre-cleaning

PXM

Home page

Cleaning

Standard

Interface Injectors

operation

InjectorsInterface

operation

Cleaning

supply

cleaning

Standard

supply

cleaning

Standard

supply

DiagnosisSettings System

supply

DiagnosisSettings System

US sieve

Settings

Alarm

Home page

Cleaning

Settings

Alarm

Standard

Interface Injectors

operation

supply

cleaning

CleaningPre-cleaning

Standard

supply

DiagnosisSettings System

US sieve

Home page

Cleaning

Settings

Alarm

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

7.7.4 MACHINE PARAMETERS DIAGNOSIS

PXM

Time

HW version

SW version

Settings System

I/O node

Device name

HW version

SW version

HW con g

LogView Diagnosis

Area

No. Description

Cycle Time Avg

Cycle Time Max

DiagnosisLogView

operation

Maintenance

cleaning

Set

Maintenance

Visu SW version

Panel hours

Diagnosis

CAN OK

SDO parameterization

Process data OK

Home page

Cleaning

Settings

Alarm

Home page

Cleaning

Settings

operation

Workstation

Position switch of linear motion unit

Powder level sensor

LogView Diagnosis

operation

cleaning

at the top Warning Minimum Cleaning

Maintenance

cleaning

DiagnosisSettings System

Alarm

Home page

Cleaning

Settings

Alarm

This side is very helpful for adjusting the position switch on the reciprocators and for testing the function of the level probe.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

Fresh powder pump

Ready Running Cleaning

PXM

Home page

Cleaning

DiagnosisLogView

operation

Interface

Emergency stop chain OK Exhaust system OK Appl. Interface: Cleaning ready Appl. Interface: Cleaning start Pressure air OK Voltage supply OK

LogView Diagnosis

operation

US Sieve

Signal Running

Signal Malfunction

Maintenance

cleaning

Maintenance

cleaning

DiagnosisSettings System

Settings

Alarm

Home page

Cleaning

Settings

Alarm

Home page

Ventilator

Signal Malfunction

LogView Diagnosis

operation

Maintenance

cleaning

DiagnosisSettings System

Cleaning

Settings

Alarm

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

Factory

Maintenance

interval

Internal FP pump

External FP pump Reset

RP pump

US Sieve

DiagnosisLogView Maintenance

Maintenance

[h]

counter

[h]

Reset

Operating

hours

[h]

PXM

Home page

Cleaning

Settings

operation

cleaning

7.7.5 SYSTEM

Factory

Change passwords

Supervisor password

Service password

Factory password

Password

Settings System

Data

backup

operation

Backup

cleaning

setting

Diagnosis

DiagnosisSettings System

Set

Exit

visualization

software

Home page

Cleaning

Settings

Alarm

1. Press the "Settings" button in the righthand menu bar to call up the page.

2. Press the "System" button to call up the page

3. The "Change passwords" page is displayed.

4. Only the password for the current level can be changed.

To change a password for another level, the level in question must  rst be activated.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

Various functions can be called up on the following pages:

– Backing up and rebooting data – Creating and booting a backup – Adapting the IP settings

PXM

Data

backup

operation

Data save / load

Load

Backup

cleaning

Completed Active Error

Operating hours

SaveSave Load

IP setting

Diagnosis

Exit

visualization

software

Home page

Cleaning

Settings

Alarm

MP Data

Version

Date

Completed Active Error

Password

Settings System

Data backup is a mechanism for the service technician to, for example, secure the set machine parameters after commissioning. This mechanism is also required during a software update.

BackUp save/load

Date

Save

Completed Active Error

Load

Home page

Cleaning

Password Backup

Data

backup

operation

cleaning

setting

DiagnosisSettings

Exit

visualization

software

System

Settings

Alarm

The backup is created automatically by the system after 24 hours of operation. Only one  le is available, which is always overwritten. Manually save by pressing the "Save" button. The time of storage is displayed by pressing the "Load" button.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

IP Settings

Obtain an IP address via DHCP

Specify an IP address

IP address:

setting

DiagnosisSettings

GET

SET

Exit

visualization

software

System

Subnet Mask:

Default Gateway:

Password Backup

Data

backup

operation

cleaning

PXM

Home page

Cleaning

Settings

Alarm

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

8 CLEANING AND MAINTENANCE

8.1 CLEANING

8.1.1 CLEANING STAFF

Cleaning work should be undertaken regularly and carefully by quali ed and trained sta . They should be informed of speci c hazards during their training.

The following hazards may arise during cleaning work:

Health hazard from inhaling powder lacquer Use of unsuitable cleaning tools and aids

PXM

8.1.2 SAFETY INSTRUCTIONS

DANGER

Explosive powder/air mixes!

Danger to life and equipment damage.

Before starting cleaning or other manual work, the high-voltage

must be shut down and locked to prevent it from being switched back on!

The spray gun must be separated from the high-voltage supply

before any cleaning work is started!

Use only electrically conductive tanks for cleaning liquids!

Ground the tank! Preference should be given to non- ammable cleaning  uids. Flammable cleaning liquids may only be used if, after switching

o the high-voltage, all high-voltage conducting parts are

discharged to a discharge energy of less than 0.24 mJ before

they can be accessed.

Most  ammable solvents have an ignition energy of around

0.24 mJ or 60 nC.

The cleaning agent's  ash point must be at least 15 K above the

ambient temperature. Only mobile industrial vacuum cleaners of design 1 (see EN 60335-2)

may be used to remove dust deposits.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only specialist sta or WAGNER Service may carry out

maintenance and repair work. Before starting work switch o the system and lock to ensure

that other people cannot switch it back on by mistake

(lock main switch on the controller). Ensure that all system components are grounded properly.

PXM

8.2 PAINT CHANGE

8.2.1 PAINT CHANGE COMPONENTS

P_02676

12345

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

8.2.2 CLEANING POSITIONS POWDER HOSES

P_02679

P_02677

Cleaning fresh powder, standard

Loss position, reclaimed powder

PXM

P_02678

Cleaning fresh powder, intensive

P_02680

Cleaning, reclaimed powder

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

8.2.3 CLEANING FUNCTIONS

Worker

PXM

Injector On

FP pump standard

FP pump intensive

US Sieve

RP hose

On O

O

End

O

Home page

Cleaning

Settings

Alarm

P_02706

1 Perform impulse  ushing of the injectors

– Interlock with guns in blowout positions (height and depth) for Pro Tech controllers 2 Clean the IP 5000 with internal cleaning program and/or preliminary clean US sieve 3 Perform pulse  ushing of the IP 5000 via the blowout device 4 Perform main cleaning of the US sieve via the blowout device 5 Perform pulse cleaning of the peristaltic pump via blowout device 6 Activate suction gun (pinch valve is opened); only in conjunction with US sieve

8.2.4 CLEANING PARAMETERS

Operate the IP 5000 fresh powder pump in accordance with the IP 5000 operating manual and "Clean fresh powder (FP)" machine parameter; see Chapter 7.7.3

Perform impulse  ushing of the injectors; see "Clean injectors" machine parameter; see Chapter 7.7.3

Perform impulse  ushing of the ultrasonic sieve; see "Clean sieve" machine parameter; see Chapter 7.7.3

Perform impulse  ushing of the peristaltic pump; see "Clean reclaimed powder (RP)" machine parameter; see Chapter 7.7.3

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

8.2.5 START CLEANING EXAMPLE: PROFITECH M

Notes for the paint change sequence:

The depicted paint change sequence represents the general principle and the procedure for a complete paint change.

Detailed steps must must be individually adapted and optimized. A possible signal exchange between the application controller and the powder

center for greater automation of the paint change sequence depends on the type of application controller used.

The required intensity of the individual paint change steps and the possible repetition of individual steps depends on the desired paint change intensity and how the powder behaves.

If the PXM is connected to a  nal  lter, then the PXM throttle valves cannot be opened when powder is introduced into the booth.

Otherwise, paint carryover may result from powder deposits in the booth/tubing. It is generally recommended to run on loss for some time (e.g. 1 minute) after a paint

change and then switch to recovery. When using powders with high amounts of pigment and wax, further measures may

be required, which must be speci ed individually. WAGNER cannot make a forecast in this regard.

PXM

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

Flat part

1. Preparation: Fresh powder, tank/box Set powder center in cleaning position

2. Blow-o guns on outside, rough cleaning of booth

3. Move guns to inside cleaning position (rear)

4. Clean the powder center, guns and fesh powder system

5. Clean the booth

6. Clean the recovery system with peristaltic pump

7. Duration [min: sec]

Cancel

Start

Guns On

Guns O

End cycle

PXM

Home page

Preparation

Load recipe

Correction

Cleaning

Recipe editor

Settings

Alarm

1. Before the start of cleaning on the powder center, the application controller must be switched over to manual or cleaning mode and paint change started there.

Paint change duration is measured from this time.

Worker

Home page

Start cleaning

Cleaning

Settings

Alarm

2. Call up the "Cleaning" menu by pressing the "Cleaning" button in the right menu bar.

3. Call up the cleaning page by pressing the "Cleaning" button.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

P_02531

4. Remove the cover from the box or tank. Injector blowing out can only be started when the enabling signal from the application

controller is cleared (if the signal exchange was activated in the con guration (Pro Tech M, Pro Tech S)).

PXM

Worker

Injector

FP pump standard

FP pump intensive

US Sieve

RP hose

On O

O

End

O

Home page

Cleaning

Settings

Alarm

5. Boot the workstation by pressing the "Up arrow" button.

6. Remove the box from the box receptacle.

7. Move the injector device downwards by pressing the "Down arrow" button on the blowout nozzles.

To do this, simultaneously press the safety switch for two-handed operation. The "Blow out injector On" button is outlined in yellow.

8. Start injector cleaning by pressing the "Blow out injector On" button. The subsequent cleaning procedure depends on whether or not the powder center

communicates with the application controller. Both versions are described below.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

Without Communication with the Application Controller:

PXM: Pressing the "OK" button is used directly as the start command

for the sequence of cleaning steps. No query is made on whether or not the pulses should begin.

Application: The application controller must be prepared before the start

of the cleaning step:

Bring the guns to the internal cleaning position (reciprocators and sliding tables)

Switch on reverse air for injectors via dosing and feed air

Example, Pro Tech M:

PXM

3. Move guns to inside cleaning position (rear)

Guns On

PXM: Injector cleaning (pulses)

1. An injector series is  ushed  rst and subsequently the other injector series.

Pre- ushing can be set (gentler with short pulses).

Application: Subsequently, if necessary, when controlling the application:

Switch o reverse air for injectors via dosing and feed air

Example, Pro Tech M:

3. Clean the powder center, guns and fesh powder system

Guns O

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

With Communication with the Application Controller:

Note: All steps are carried out without operator intervention.

PXM Exam., MCM

PXM output: "Blow out injectors active" (terminal X2:15) is set to "HIGH".

After the "PC cleaning ready" signal comes from the application controller, the PXM performs injector cleaning.

PXM input: "Release blow out injectors" (terminal X2:19).

Performing injector cleaning: An injector series is  ushed  rst and

subsequently the other injector series. Pre- ushing can be set (gentler with short

pulses). PXM output: "Blow out injectors active"

(terminal X2:15) is set to "LOW". The PXM signals the end of internal cleaning.

The powder center sets the "Request PC cleaning" MCM input (terminal X20:13) to "HIGH".

It is advanced by one cleaning step. The MCM performs pre- ushing (feed and

dosing air of the injector are controlled by pulses).

The duration can be con gured in the machine parameters.

The motion technology is also moved to the cleaning position.

The MCM subsequently switches on the reverse air for internal cleaning (feed and dosing air).

The MCM sets the "PC cleaning ready" output (terminal X20:15) to "HIGH".

The powder center brings the "Request PC cleaning" MCM input (terminal X20:13) to "LOW".

The reverse air for internal cleaning (feed and dosing air) are switched o .

The MCM carries out part 2 of exterior cleaning.

PXM

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

Worker

PXM

Injector

FP pump standard

FP pump intensive

US Sieve

RP hose

On O

O

End

O

Home page

Cleaning

Settings

Alarm

9. The end of injector cleaning is displayed by a white "Blow out injector On" button and a yellow "Blow out injector O " button.

10. Clean the ultrasonic sieve if necessary.

P_02535

11. Clean the IP 5000 fresh powder pump. There is the possibility of normal cleaning here (during tone-in-tone paint changes)

or intensive cleaning. Note: When connecting the PXM to a  nal  lter, no powder may be whirled/blown

o in the booth during this time.

12. "Standard" cleaning sequence: Put suction lance in the park position (depicted left) and snap into the clamp.

13. Plug the feed hose in the park position (pictured right).

14. Press "FP pump Standard On" button; the pump's own cleaning program is running.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

Worker

Bring suction lance and FP hose

to park position.

15. A con rmation message appears.

16. "FP-intensive" cleaning sequence: put suction lance, as in workstep 13, in the cleaning position.

17. Use an adapter to plug the feed hose onto the blowout coupling.

PXM

P_02594

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

18. Press "FP pump Intensive On" button. A combined cleaning program with pump and blowout pulses is running according

to the time set in the pump.

Worker

PXM

Injector

FP pump standard

FP pump intensive

US Sieve

RP hose

On O

O

End

O

Home page

Cleaning

Settings

Alarm

19. The end of fresh powder pump cleaning is displayed by a white "Clean FP pump On" button and a yellow "Clean FP pump Off" button.

P_02537

20. Clean the peristaltic pump. Open cyclone and swivel out sieve (pictured left). Plug the reclaimed powder hose onto the blowout coupling (pictured right).

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

Worker

PXM

Injector

FP pump standard

FP pump intensive

US Sieve

RP hose

On O

O

End

O

Home page

Cleaning

Settings

Alarm

Press "RP hose cleaning On" button to start cleaning the reclaimed powder hose. The end of reclaimed powder hose cleaning is displayed by a white "Clean RP hose

On" button and a yellow "Clean RP hose O " button.

21. Press the "End" button to finish cleaning.

22. Blow out the cyclone and the cyclone sieve.

23. Close the cyclone funnel several times, wait 15 seconds, open and blow out to remove residual dust from the cyclone.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

8.2.6 CLEANING/PAINT CHANGE ON THE PXM WITH ULTRASONIC SIEVE

Notes for the paint change sequence:

The ultrasound sieve can be cleaned either manually or using existing cleaning components. Three steps are planned:

Coarse cleaning using the internal cleaning program of the IP 5000 fresh powder pump. The screen frame can remain installed.

Main cleaning with blowout device and compressed air pulses (see Cleaning Parameters, Chapter 6.9.2). The sieve frame must be replaced with a dummy frame to avoid damage to the sieve fabric.

Perform a manual  nal cleaning of the individual components.

PXM

Injector blow out On

P_02682

1. Plug the outlet hose to the park position.

2. Clean IP 5000 internally.

US Sieve

RP hose

Worker

On O FP pump standard

On O FP pump intensive

On O

O

Home page

End

Cleaning

O

Settings

Alarm

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

P_02684

3. Remove the connections from the cover.

4. Put the cover aside.

5. Remove the sieve frame and hang it on the side wall.

6. Insert the dummy frame.

7. Put the cover on again.

PXM

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

PXM

Worker

P_02685

Injector blow out On

US Sieve

RP hose

On O FP pump standard

On O FP pump intensive

On O

O

8. Plug the blowout hose onto the peristaltic pump connection.

9. Remove the fresh powder hose and to plug onto the blowout position (below).

10. Plug the dummy plugs onto the fresh powder connection.

11. Select main cleaning of the US sieve.

Home page

End

Cleaning

Settings

Alarm

P_02686

12. Remove all connections from the sieve cover.

13. Blow out the sieve cover.

14. Suction clean the sieve funnel with the suction gun and blow it out with the blow gun.

15. Remove outlet hose and blow through.

16. Blow o sieve.

17. Mount all components again.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

8.3 MAINTENANCE

8.3.1 MAINTENANCE STAFF

Maintenance work should be undertaken regularly and carefully by quali ed and trained sta . They should be informed of speci c hazards during their training.

The following hazards may arise during maintenance work:

Health hazard from inhaling powder lacquer Use of unsuitable tools and aids Danger due to residual pressure in compressed-air lines

Once the maintenance work is complete, the device must be checked by a quali ed person to ensure a reliable condition.

PXM

8.3.2 SAFETY INSTRUCTIONS

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may

carry out repairs and replace parts.

Only repair and replace parts that are listed in the Chapter

"Spare parts" and that are assigned to the unit.

Before all work on the device and in the event of work

interruptions:

- Switch o the energy supply and the compressed air supply.

- Relieve spray gun and device pressure.

- Secure the spray gun against actuation. Observe the operating and service manual for all work.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

8.3.3 MAINTENANCE PROCEDURES

The maintenance intervals should be adapted by the operator depending on the level of use and if necessary the level of soiling. If in doubt, we recommend contacting J. Wagner AG's specialist personnel. The valid health and safety speci cations and safety instructions provided in Chapter 4 must be adhered to for all maintenance work.

Maintenance work Time stamp

Check ultrasonic sieve cloth * per shift Check  uid unit per shift Check the air hose of level probe for blockages per shift Check that the  uid rods of the workstation are not bent weekly Check that the  uid rods  uidize evenly weekly Check injectors weekly Check integrated IP 5000 fresh powder pump weekly Check  lter cartridges for secure  t and retighten if necessary monthly

PXM

* For more information, see ultrasonic sieve operating manual

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

8.3.4 SAFETY CHECKS

8.3.4.1 GROUNDING CHECK

Every day

Before starting work, carry out a visual check to ensure that the system is grounded.

PXM

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

9 TROUBLESHOOTING AND RECTIFICATION

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may

carry out repairs and replace parts.

Only repair and replace parts that are listed in the Chapter

"Spare parts" and that are assigned to the unit.

Before all work on the device and in the event of work

interruptions:

- Switch o the energy supply and the compressed air supply.

- Relieve spray gun and device pressure.

- Secure the spray gun against actuation. Observe the operating and service manual for all work.

PXM

9.1 FAULT MESSAGES

The "Alarm" function can be used to display the fault messages. Either the fault active at that time or all fault messages can be displayed. The date, reset time, module, fault code, and a brief text are displayed.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

9.2 TYPES OF FAULT MESSAGES

Warnings:

Warning messages are displayed in yellow in the visualization but do not cause the system to be stopped. The warning is reset automatically (without acknowledgement) when the warning state has been resolved.

Faults:

Error messages are displayed in red in the visualization. Faults cause the system to be stopped.

System stop in the case of faults:

Reaction to a fault in the system:

Faulty devices are switched o and the "Powder center OK" outlet is set to "LOW".

PXM

9.3 CURRENT

Worker

Time No. Description

Wagner bigbag: malfunction

Warning linear motion unit not referenced ==> Move to the top manually

Current History

Con rm

Home page

Cleaning

Settings

Alarm

1. Press the "Alarm" button in the right-hand menu bar to activate the function.

2. The "Current alarms" page is displayed.

3. To reset the error, press the "Con rm" button.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

9.4 HISTORY

PXM

Worker

Time No. Description

Reset time

I/O module: Changed hardware con guration

Save as

*.csv

Current History

Save as

*.xml

Home page

Cleaning

Settings

Alarm

1. Press the "History" button in the bottom function bar to activate the function.

2. The "History" page is displayed. All fault messages are displayed.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

Malfunction Cause Remedy

Warning Powder shortage Powder shortage detected by

the sensor at the workstation in automatic mode

Warning predetection powder shortage

Warning linear motion unit not referenced motion unit upward manually

Powder shortage

Problems in the linear motion unit Timeout when moving the linear

Problems during position detection of the linear motion unit

Pulsing powder cloud, spitter

Level detection does not work properly

Move the linear

Predetection powder shortage detected at the workstation in automatic mode

Controller rebooted The controller does not know in which segment the linear motion unit is located; that is why the upper position switch must be actuated  rst. That is why the operator must move the linear motion unit upwards with the "Up arrow" button.

Powder shortage detected by the sensor at the workstation in automatic mode

motion unit

Multiple position switches deliver a "1" simultaneously

Too low or too high  uidization Set  uidization Fluid rods bent/defective Align  uid rods horizontally;

Poorly  uidizable powder Use another powder Total air of the injector too low Set the total air on the application

Air sensor tube clogged Disconnect air coupling and

No air  ow from the sensor tube Contact the WAGNER Service Team Limit switch incorrectly set or

defective

Check whether the feed is enabled and running

Replace fresh powder box Advance warning Only for

display to the operator Provide fresh powder box Move linear motion unit upwards

with the "Up arrow" button

Acknowledge warning

Check whether the feed is enabled and running

Provide enough fresh powder Check position switch of the linear

motion unit Move linear motion unit in jog

mode and check whether the linear motion unit is running correctly

Check position of the position switch

replace if necessary

controller

blow out tube downwards

Check limit switch and adjust

PXM

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

Malfunction Cause Remedy

Control button on the touch screen does not respond

Screen performance too low

No release; button must be outlined in yellow

Mesh width too small Use sieve frame with larger mesh

Sieve mesh is clogged Clean sieve mesh

Sieve mesh damaged Have sieve frame restrung Sieve mesh has no tension Have sieve frame restrung

Check conditions for release Function is not performed since

the switching element is defective in the control cabinet

Too little pressure in the compressed air supply

width

Have sieve frame restrung

PXM

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

10 REPAIR

10.1 REPAIR PERSONNEL

Repair work should be undertaken carefully by quali ed and trained personnel. They should be informed of speci c hazards during their training.

The following hazards may arise during repair work:

- Health hazard from inhaling solvent vapors

- Use of unsuitable tools and aids

A skilled person must check to ensure that the device is in a reliable state after it is repaired.

10.2 SAFETY INSTRUCTIONS

PXM

Observe the safety instructions in Chapter 4 and Chapter 8.1.2.

Before a Repair

- Flush and clean the system.

After a Repair

- Carry out a safety checks in accordance with Chapter 8.2.4.

Chapter 8.1.3.

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may

carry out repairs and replace parts.

Only repair and replace parts that are listed in the Chapter

"Spare parts" and that are assigned to the unit.

Before all work on the device and in the event of work

interruptions:

- Switch o the energy supply and the compressed air supply.

- Relieve spray gun and device pressure.

- Secure the spray gun against actuation. Observe the operating and service manual for all work.

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

The following repairs can be carried out as needed:

Replacing the O-ring on the blowout station for the injectors in case of leaks

P_02586

Replace scraper rings on the guide bushings of the intake tubes Replace  uid tubes

PXM

P_02587

Replace the solenoid valves on the pressure tank of the blowout device

P_02588

Replace the solenoid valves of the  lter suction Replace transvector to the guide tubes of the injector holding plate (mounted on the

roof) Check the wearing parts on the injectors and replace if necessary in accordance with

the Injectors operating manual Check the wearing parts of the IP 5000 and replace if necessary in accordance with the

IP 5000 operating manual

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

11 FUNCTION TEST AFTER THE REPAIR

All functions must be checked in manual and automatic mode.

PXM

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

12 INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: 2010

If the system is used for electrostatic coating with  ammable coating powders, testing should be undertaken in accordance with DIN EN 50177: 2010-04 as per Table 3 and Table4.

PXM

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

PXM

Type of inspection Inspection

interval

continuously

TP/SP

indicator.

Measurements of air  ow speed /

air quantities

Check the di erential pressure

annually

stopped and the product supply,

Test whether the system is safely

supply air and high-voltage are

switched o when the ventilation

is shut down.

weekly

Inspect and test (e.g. by

measuring) whether all high-

result in a discharge that puts

people at risk.

voltage carrying parts do not

FT = Function test

ME = Measurement

OC = Organization check

VI = Visual inspection

CM = Constant monitoring

TT = Technical testing

Section Type of inspection Requirements Inspection

technical ventilation

Checking the e ectiveness of

technical ventilation

1 Checking the e ectiveness of

feed and high-voltage cannot be

interlocked such that the powder

The technical ventilation should be

equipment and high-voltage,

2 Link between technical ventilation

ventilation is not working e ectively.

switched on, while the technical

material supply

compressed air and coating

Parts carrying high-voltage outside

the spray area must be routed such

that discharges which put people at

risk do not occur.

the spray area

3 Parts carrying high-voltage outside

Legend:

ER = Employer

MF = Manufacturer

FPO = Fire prevention o cer

ELT = Electrician

SP = Skilled person

TP = Trained person

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

PXM

interval

Type of inspection Inspection

weekly

VI/ME/CM

Visual check of ground

connections, perform function

test on grounding switch,

measurement of grounding

weekly

Measurement of discharge

resistors.

energy.

SP ME/CM

weekly

Measure resistance to ground

SP ME/CM

potential)

(work piece receiver - ground

max. 1 megohm @ 1000 V.

FT = Function test

ME = Measurement

OC = Organization check

VI = Visual inspection

CM = Constant monitoring

TT = Technical testing

Section Type of inspection Requirements Inspection

transport equipment, work

elements, such as  oors, walls,

4E ectiveness of grounding All the system's conductive

pieces, powder tanks, machines or

ceilings, protective grating,

which carry high-voltage during

area, with the exception of parts

construction parts etc. in the spray

the grounding system. Parts of

operation, must be connected to

If su cient grounding of

the booth must be grounded in

accordance with EN 12215.

5 Measures to take if conductive

must not exceed the permissible

conductive parts cannot be

components are insu ciently

value.

ensured, their discharge energy

grounded

The resistance to ground of

6 Ground leaking resistance from the

must not exceed 1 megohm

every work piece's locating point

(measurement voltage must be

workpiece attachment point

remain grounded during coating.

of the workpiece mount must

guarantee that the workpieces

1000 V). The form of construction

Legend:

MF = Manufacturer

ER = Employer

FPO = Fire prevention o cer

SP = Skilled person

ELT = Electrician

TP = Trained person

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

13 DISASSEMBLY AND DISPOSAL

We recommend having the WAGNER system disassembled by WAGNER or another specialist.

Before starting disassembly, all supply media (electric current, compressed air) must be disconnected at the connection points. All powder lacquer lines must be completely emptied and then rinsed. Lacquer residues must be disposed of in line with statutory requirements.

Before starting disassembly, check whether the supply lines have actually been interrupted and have been depressurized and/or de-energized if necessary.

The empty system should be thoroughly cleaned. In particular,  re loads, such as unused lacquers in exhaust air pipes, etc. for example, should be removed to keep the risk of  re during disassembly as low as possible.

PXM

We recommend reporting to the public authorities the fact that systems with mandatory approval requirements are decommissioned.

Separate all materials encountered during disassembly as clearly as possible in line with statutory requirements. Take appropriate actions to ensure that no dangerous substances enter the system during disassembly. All waste produced must be separated and disposed of in line with local requirements.

Used materials are:

Steel PVC synthetic material Cable ...

VERSION 08/2015 ORDER NUMBER DOC2350372

OPERATING AND ASSEMBLY MANUAL

14 ACCESSORIES

Cover for  uid tank (without sieve) PXM 20/22 Order No. 2350986

P_02548

PXM

P_02707

P_02549

Cover for  uid tank (with sieve) PXM 20/22 Order No. 2357417

Cover for box (without sieve) PXM 20/22 Order No. 2350989

Cover for box (with sieve) PXM 20/22 Order No. 2353300

P_02708P_0270

100

WAGNER PXM, PI-F1, Hi-Coat ED, IP 5000, EPG S2 Operating And Assembly Manual

Specifications and Main Features

Frequently Asked Questions

User Manual