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II 3D Ex tc IIIB T60°C Dc
Pro Tech M
Hardware + Installation
Version 07 / 2014
Translation of the Original
Operating Manual
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ProfiTech M
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
Table of Contents
1 GENERAL 6
1.1 Preface 6
1.2 Warnings, Notices, and Symbols in this Operating Manual 6
1.3 Languages 7
1.4 Abbreviations 7
1.5 Terminology for the Purpose of this Manual 8
2 CORRECT USE 9
2.1 Device Type 9
2.2 Type of Use 9
2.3 Use in Potentially Explosive Areas 9
2.4 Safety Parameters 9
2.5 Processible Working Materials 10
2.6 Reasonably Foreseeable Misuse 10
2.7 Residual Risks 10
3 IDENTIFICATION 11
3.1 Explosion Protection Identi cation 11
3.1.1 MCM Master Control 11
3.1.2 MCM CPS I/O Control 11
3.2 Type Plate 12
4 GENERAL SAFETY INSTRUCTIONS 13
4.1 Safety Instructions for the Operator 13
4.1.1 Electrical Devices and Equipment 13
4.1.2 Sta Quali cations 13
4.1.3 Safe Work Environment 13
4.2 Safety Instructions for Sta 14
4.2.1 Safe Handling of WAGNER Powder Spray Devices 14
4.2.2 Grounding the Device 14
4.2.3 Product Hoses 14
4.2.4 Cleaning 15
4.2.5 Handling Powder Lacquers 15
4.3 Protective and Monitoring Equipment 15
4.4 Safety Feature Identi cation 16
5 DISCLAIMER 17
5.1 Hardware 17
5.2 Software 17
6 COMPONENT DESCRIPTION 18
6.1 Functional Description 18
6.2 Protective and Monitoring Equipment 18
6.3 Scope of Delivery 18
6.4 MCM Controller Components 19
6.5 Control Unit/Spray Gun Components 22
6.6 Pulse Generator Components 25
6.7 Light Grid Set LGS 25 Components 26
6.8 Kontur 2 Light Curtain Components 26
6.9 Light curtain CML720i Components (from 06/2014) 28
6.10 Motion Equipment Components 30
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Table of Contents
6.11 Miscellaneous 31
6.12 Technical Data 32
6.12.1 MCM Master Control 32
6.12.2 MCM CPS I/O Control 33
6.12.3 Technical Data for Maximum Pro Tech M Con guration 34
6.12.4 Rack (10 EPG S2) 35
6.12.5 EPG S2 35
6.12.6 EPG-Sprint X 36
6.13 Compressed Air Quality 37
6.14 Operating Elements on the Master Module 38
6.15 Display Elements Front Side of EPG S2 39
7 ASSEMBLY AND COMMISSIONING 40
7.1 Training the Assembly Sta 40
7.2 Storage Conditions 40
7.3 Installation Conditions 40
7.4 Assembly of the Pro Tech M Components 41
7.5 Setting Up the Rack 42
7.6 System Description 43
7.6.1 CPS Control Cabinet Design 43
7.6.2 Terminal Descriptions 44
7.6.3 CAN Addresses for MCM System 47
7.7 Connecting the MCM Module 48
7.7.1 Connections on the MCM Master Control 49
7.7.2 Connections on the MCM CPS I/O Control 49
7.7.3 Connection Point for CAN Bus, EPG-Sprint X and Encoder 50
7.8 Connections in the Rack 51
7.9 Connecting the Automatic Spray Guns on the EPG S2 52
7.10 Connecting the Manual Guns to the EPG-Sprint X 53
7.10.1 Signals on the EPG-Sprint X 54
7.10.2 Parameter Setting on the EPG-Sprint X 54
7.11 Power Supply of the EPG Control Units 55
7.12 Connecting the Conveyor Encoder 56
7.13 Connecting the Light Curtains 57
7.13.1 Connection Diagram for "Kontur 2" Light Curtains 57
7.13.2 Installation of the "Kontur 2" Light Curtains 59
7.13.3 Connection Diagram for LGS Light Grid 61
7.13.4 Assembly of CML720i Light Curtains 62
7.13.5 Connection Diagram for CML720i Light Curtains with Code Catching 64
7.13.6 Connection Diagram for CML720i Light Curtains without Code Catching 66
7.13.7 Connection Diagram for CML720i Height Light Curtains 67
7.13.8 Grounding of CML720i Light Curtains 68
7.14 Commissioning the CML720i Light Curtains 69
7.14.1 Setting the Baud Rate 72
7.14.2 Setting Node ID 74
7.14.3 Alignment Operation 76
7.15 Connection of the Motion Technique 78
7.15.1 Connections with Two Motion Units 79
7.15.2 Connections with Four Motion Units 80
7.15.3 Setting Node ID's and Baud Rate on Sliding Table 81
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Table of Contents
7.15.4 Setting Node ID and Baud Rate on Reciprocator 82
7.15.5 Connecting Spray Gun Blow Out Fixture 83
7.16 Grounding 84
7.17 Commissioning 86
8 OPERATION 87
8.1 Training the Operating Sta 87
8.2 Safety Instructions 87
8.3 Work 88
8.3.1 Starting / Ending Coating Operation 88
9 CLEANING AND MAINTENANCE 89
9.1 Cleaning 89
9.1.1 Cleaning Sta 89
9.1.2 Safety Instructions 89
9.1.3 Cleaning Procedures 90
9.2 Maintenance 91
9.2.1 Maintenance Sta 91
9.2.2 Safety Instructions 91
9.2.3 Safety Checks 92
9.2.3.1 Grounding Check 92
9.2.4 Maintenance Procedures 92
10 INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: 2010 93
11 DISASSEMBLY AND DISPOSAL 97
11.1 Disassembly 97
12 SPARE PARTS 98
12.1 How Can Spare Parts Be Ordered? 98
12.2 Spare Parts Recommendation for the Control Cabinet 99
13 EXTENDED OPERATING MANUAL 100
14 WARRANTY AND CONFORMITY DECLARATIONS 102
14.1 Important Notes Regarding Product Liability 102
14.2 Warranty Claim 102
14.3 CE Declaration of Conformity 103
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1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL
1 GENERAL
1.1 PREFACE
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.
Note - provides information about particular characteristics and how to proceed.
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.
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.
HINT
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 operating and service
sta .
The device may only be operated by trained sta and in compliance with this operating
manual.
Operating and service sta 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.
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OPERATING MANUAL
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This operating manual describes the components and installation of a Pro Tech M system
(control cabinet, electrical connections and preparation for rst commissioning).
This operating manual is to be used alongside the Pro Tech M "System Operation"
operating manual , which describes the operation of the entire Pro Tech M system.
1.3 LANGUAGES
The operating manual is available in the following languages:
German 2335143 English 2335144
French 2335145 Italian 2335146
Spanish 2335147 Russian 2350911
1.4 ABBREVIATIONS
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Spare part
W Width
H Height
D Depth
RP Reversal point
LC Light curtain
I/O Input/Output
OK all right
Trigger point
ASR Automatic sine regulation
MP Machine parameters
REZ Recipe parameter
FC Frequency converter, e.g. for motion equipment
Master Control Module = abbreviation for Pro Tech M
SR Shift register
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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning Manual cleaning of devices and device parts with cleaning
agent
Flush 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
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.
Electrician Can assess the work assigned to him/her and detect possible
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
Skilled person A person, who, based on his/her technical training, experience
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.
In accordance with
TRBS 1203 (2010)
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OPERATING MANUAL
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2 CORRECT USE
2.1 DEVICE TYPE
2.2 TYPE OF USE
The Pro Tech M controller serves to control the powder coating system's spray guns,
powder conveying device, reciprocators, and sliding table.
2.4 SAFETY PARAMETERS
2.3 USE IN POTENTIALLY EXPLOSIVE AREAS
Controller for automatic powder coating systems
The Pro Tech M controller may be used in the dust explosion zone (Zone 22) under the
following conditions (see explosion protection identi cation in Chapter 3.1).
All connections and cable entries not needed (mains output, remote control) are
sealed with dust protection caps.
WAGNER accepts no liability for any damage arising from non-intended 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 sta must be trained based on 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 regulations standards in the
country of use must be observed.
The automatic coating system may only be used if all parameters are set and all
measurements/safety checks are carried out correctly.
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2.6 REASONABLY FORESEEABLE MISUSE
2.5 PROCESSIBLE WORKING MATERIALS
Types of powder which can be charged electrostatically
Metallic powder
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
Handling powder
lacquers and
cleaning agents
Skin irritations, Wear protective
clothing,
Operation,
allergies observe safety data
sheets
maintenance,
disassembly
Powder lacquer
in air outside the
de ned working
area
Lacquering
outside the
de ned working
area
Inhalation of substances
which are hazardous to
health
Observe work and
operation instructions
Operation,
maintenance
The forms of misuse listed below may result in physical injury or property damage:
Coating work pieces which are not grounded;
Unauthorized conversions or modi cations to the system;
Working with liquid coating products or moist powder lacquer;
Using defective components, spare parts or accessories other than those described in
the "Accessories" chapter of this operating manual;
Continuing work with a defective or kinked product hose;
Working with incorrectly set values;
Processing food.
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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
3.1.1 MCM MASTER CONTROL
3.1.2 MCM CPS I/O CONTROL
The device is suitable for use in potentially explosive areas (Zone 22).
All connections and cable entries not needed must therefore be sealed.
System type: Pro Tech M controller
Manufacturer: J. Wagner AG
CH - 9450 Altstätten
II 3D Ex tc IIIB T60° C Dc
CE: European Communities
Ex: Symbol for explosion protection
II: Device class II
3: Category 3
D: Ex-atmosphere dust
tc: Protection provided by housing, device protection level according
to DIN EN 60079-31
IIIB: Maximum surface temperature
Dc: Device protection level, suitable for use in Zone 22
System type: Pro Tech M controller
Manufacturer: J. Wagner AG
CH - 9450 Altstätten
II 3D Ex tc IIIB T60° C Dc
CE: European Communities
Ex: Symbol for explosion protection
II: Device class II
3: Category 3
D: Ex-atmosphere dust
tc: Protection provided by housing, device protection level according
to DIN EN 60079-31
IIIB: Maximum surface temperature
Dc: Device protection level, suitable for use in Zone 22
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ProfiTech M
Type / Typ:
Serie Nr.:
Serial No.:
Eingangsspannung:
Input Voltage:
Eingangsleistung:
Input Power:
MCM Master Control
24VDC
max. 17 W
Baujahr:
Year of manufactur:
J. Wagner AG
CH 9450 Altstätten
Made in Switzlerland
II 3D
Ex tc IIIB T60ºC Dc
Type / Typ:
Serie Nr.:
Serial No.:
Eingangsspannung:
Input Voltage:
Eingangsleistung:
Line Power:
Vorsicherung:
Main fuse:
MCM CPS I/O Control
230/400VAC 50/60Hz
max. 5.1kW
35A
Baujahr:
Year of manufactur:
J. Wagner AG
CH 9450 Altstätten Made in Switzerland
II 3D
Für den Betrieb in Zone 22 müssen
alle Kabeleinführungen durch ein
Kabel oder Stopfen verschlossen sein.
For operation in Zone 22 all cable
grommets must be closed with a
cable or a plug.
Ex tc IIIB T60ºC Dc
P_02465
1
2
1
3
2
3
4
5
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
3.2 TYPE PLATE
1 Serial number
2 Input voltage
3 Input power
4 Back-up fuse
5 Explosion protection information
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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
4.1.2 STAFF QUALIFICATIONS
4.1.3 SAFE WORK ENVIRONMENT
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident prevention.
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.
Ensure that the device is operated, maintained and repaired only by trained persons.
The oor in the working area must be electrostatically conductive (measurements
according to EN 1081 and EN 61340-4-1).
The footwear worn by the operators must comply with the requirements of
EN ISO 20344. The measured insulation resistance must not exceed 100 megohms.
The protective clothing, including gloves, must comply with the requirements of
EN ISO 1149-5. The measured insulation resistance must not exceed 100 megohms.
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.
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4.2.1 SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES
4.2.2 GROUNDING THE DEVICE
4.2.3 PRODUCT HOSES
4.2 SAFETY INSTRUCTIONS FOR STAFF
Only use an original Wagner powder hose.
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.
Ensure that all persons inside the working area are grounded, e.g., by wearing
electrostatically conductive shoes.
The functionality of grounding cables must be checked regularly (see EN 60204).
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!
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.
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4.2.4 CLEANING
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.
Take 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).
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
0.24mJ 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.
4.3 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.
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4.4 SAFETY FEATURE IDENTIFICATION
Plates bearing information for the user have been attached to the work openings of the
powder coating booth.
The plate size corresponds to the standard category Ø 100 mm; 3.94 inches.
The label plates, which must be attached, are shown below:
High-voltage!
In the control cabinet:
(25 mm; 0.98 inch) voltage
before main switch
Forbidden for unauthorized
persons!
Explosive atmosphere!
Forbidden for persons
with a cardiac pacemaker!
Follow the instructions in
the operating manual!
Smoking, re, and open
ames are prohibited!
Wear electrostatically
conductive footwear!
Danger of crushing!
Risk of tripping!
Do not jump on the
booth oor!
Danger of slipping!
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Any amendments by the user or any third party to the structure of the control cabinet
delivered by J. WAGNER GmbH, in particular in respect of the electric controller, require the
written permission of J. WAGNER GmbH.
Any amendments, which were not permitted, immediately lead to the exclusion of all
warranty, liability and guarantee claims by the manufacturer.
5 DISCLAIMER
5.1 HARDWARE
5.2 SOFTWARE
The production of software copies intended for sale or installation in the end user's
proprietary systems or controllers intended for sale or for internal use requires the written
permission of J. WAGNER GmbH.
Any amendments by the user or third parties of the software delivered by J. WAGNERGmbH,
requires the written permission of J. WAGNER GmbH.
Any amendments, which were not permitted, immediately lead to the exclusion of all
warranty, liability and guarantee claims by the manufacturer.
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6 COMPONENT DESCRIPTION
6.1 FUNCTIONAL DESCRIPTION
The Pro Tech M controller is used in automatic coating systems. The controller controls:
Powder output quantity
Powder atomization
High-voltage
Current limitation
Motion technology
Gap control
Height control
Depth control
Quantity Order No. Designation
1Pro Tech M controller, consisting of:
1 2330000 MCM Master Control
1 2330001 MCM CPS I/O Control
1 2330002 MCM cable set 10 m
The standard equipment includes:
1 2335279 Declaration of Conformity
1 2335143 Operating manual, German
1 see Chapter 1.3 Operating manual in local language
6.3 SCOPE OF DELIVERY
6.2 PROTECTIVE AND MONITORING EQUIPMENT
Protective and monitoring equipment!
Risk of injury and damage to the device.
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.
WARNING
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6.4 MCM CONTROLLER COMPONENTS
MCM Master Control Module: Order No. 2330000
The MCM Master Control Module serves as an operating unit and
as a controller
MCM CPS I/O Control Module: Order No. 2330001
The Control Module serves as supply and input/output module
Main switch: Order No. 2331260
Main switch, 3-pin 11.5 kW for AC supply of MCM CPS I/O Control
Module
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P_02191
OPERATING MANUAL
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MCM cable set 10 m; 32.8 ft: Order No. 2330002
Cable set for connection of master module and
controller module
Consists of:
MCM CAN BUS connection cable 10 m Order No. 2330005
2330005
MCM connection cable 16-pin 10 m Order No. 2330006
2330006
MCM connection cable 4-pin 10 m Order No. 2330007
2330007
CAN bus extension cable
CAN bus cable M12 plug / coupling PVC 0.6 m Order No. 2320127
CAN bus cable M12 plug / coupling PVC 2 m Order No. 2320128
CAN bus cable M12 plug / coupling PVC 5 m Order No. 2320129
CAN bus cable M12 plug / coupling PVC 10 m Order No. 2320130
CAN bus cable M12 plug / coupling PUR 15 m Order No. 2328556
CAN bus cable M12 plug / coupling PUR 20 m Order No. 2328557
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P_02192
P_02193
OPERATING MANUAL
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CAN bus termination Order No. 2321402
for EPG S2 and external extension
CAN bus termination Order No. 2338042
for light curtain and motion technology
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6.5 CONTROL UNIT/SPRAY GUN COMPONENTS
Rack: Order No. 2328670
The rack includes:
Air distributor complete 10 x 1" Order No. 2326124
Hose
5.5/8 mm, 10 m Order No. 9982078
Base rack for a maximum of 10 EPG S2 control units
The main air valve must be controlled with the MCM in order to
achieve the interlock with the main air monitoring.
EPG-S2: Order No. 2316991
Universal control unit for Corona or Tribo powder spray guns or
eld controller
One EPG S2 can control two spray guns.
A maximum of 16 EPG S2 double modules can be connected to an
MCM system (maximum 32 automatic guns).
Automatic guns:
Corona spray guns: PEA-C3, PEA-C4,
PEA-C4 Twin
PEA-C3XL, PEA-C4XL
Tribo spray guns: PEA-T3
PEA-T3XL
EPG-Sprint X Order No. 2324731
Universal control unit for Corona or Tribo powder spray guns or
eld controller
One EPG-Sprint X is required per gun.
A maximum of two EPG-Sprint X control units can be connected to
an MCM system with manual guns.
Manual guns:
Corona spray gun: PEM-X1, PEM-C4
Tribo spray gun: PEM-T3
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Shelf (base): Order No. 2328668
Blanking plate: Order No. 2328669
To close free spaces when the frame is not fully tted.
Connection set EPG S2: Order No. 2321529
CAN bus cable 0.6 m; 1.97 ft Order No. 2320127
Mains cable 0.55 m; 1.80 ft Order No. 241269
Grounding cable Order No. 360254
Hose
6 / 8 mm; 0.32 inch black Order No. 9982078
Hose connection between the air di user of the rack and the control
units.
Power supply cable 10 m; 32.8ft Order No. 360263
Electrical supply cable to the rst EPG S2 or EPG-Sprint X
(with plug to the EPG)
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ProfiTech M
P_02189
OPERATING MANUAL
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Sprint connection cable
The connection cable is required to connecting the EPG-Sprint X
control unit.
Connection cable 10 m; 32.8 ft Order No. 2335605
Terminating resistor Order No. 2321402
Hose
4/6 mm Order No. 9982079
Hose connection between EPG S2/EPG-Sprint X and spray gun
Hose
6/8 mm red Order No. 9982063
Feed air hose from EPG S2/EPG-Sprint X to powder injector
Hose
6/8 mm blue Order No. 9982062
Dosing air hose from EPG S2/EPG-Sprint X to powder injector
Powder hose
Powder hose from the powder injector to the spray gun
Inside diameter:
9 mm Order No. 351794
10 mm Order No. 2310699
11 mm Order No. 2307502
12 mm Order No. 2310700
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ProfiTech M
P_01957
P_02188
P_01958
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
6.6 PULSE GENERATOR COMPONENTS
Encoder Order No. 2335582
Hollow shaft encoder 24V/100 pulses
Bracket set for encoder Order No. 2335512
Connection cable for encoder Order No. 2336565
Connection cable, tailored 30 m
Cable with plug and coupling, extendible
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P_02191
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
6.7 LIGHT GRID SET LGS 25 COMPONENTS
Light grid set LGS 25, 300 mm Order No. 2330170
Consists of:
Light grid LGS 25 300 mm, switching output
Mounting support
Connection cable transmitter 25 m; 4 x 0.34
Connection cable receiver 20 m; 8 x 0.25
6.8 KONTUR 2 LIGHT CURTAIN COMPONENTS
"Kontur 2" light curtain (resolution 10 / 40 mm)
Order No. Order No.
Length (mm; inch) Resolution 20 mm Resolution 40 mm
320; 12.60 3158584 3127544
480; 18.90 3158585 3127327
640; 25.20 3158586 3127549
960; 37.80 3158587 3127552
1,280; 50.40 3158588 3127555
1,600; 62.99 3158589 3127024
1,920; 75.60 3158590 3127328
2,240; 88.19 3158591 3127689
2,560; 100.79 3158592 3127564
Light curtain/Quattro connection cable 3158597
Length 2.5 m; 8.20 ft
Light curtain/Quattro connection cable 3158598
Length 5.0 m; 16.40 ft
CAN connection cable 2328557
Length 20.0 m; 65.62 ft
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Quattro CAN open control unit for light curtain
Order No. 2330630
Power supply cable to "Kontur 2" light curtain
Per meter 3x1.0 mm² Order No. 3052605
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P_02455
P_02456
P_02457
P_02458
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
"CML720i" light curtain (resolution 10 / 20 / 40 mm)
Module comprising light curtain, transmitter and receiver, 2brackets,
Y cable for supply and Y cable for CAN bus
Type Length / beam spacing Order No.
CML720i 160/05 S+T 160 mm / 5 mm 2345151
CML720i 480/10 S+T 480 mm / 10 mm 2345970
CML720i 1600/10 S+T 1,600 mm / 10 mm 2345971
CML720i 310/20 S+T 310 mm / 20 mm 2345152
CML720i 470/20 S+T 470 mm / 20 mm 2345153
CML720i 630/20 S+T 630 mm / 20 mm 2345154
CML720i 950/20 S+T 950 mm / 20 mm 2345155
CML720i 1270/20 S+T 1,270 mm / 20 mm 2345156
CML720i 1590/20 S+T 1,590 mm / 20 mm 2345157
CML720i 1910/20 S+T 1,910 mm / 20 mm 2345158
CML720i 2230/20 S+T 2,230 mm / 20 mm 2345159
CML720i 2550/20 S+T 2,550 mm / 20 mm 2345160
CML720i 2870/20 S+T 2,870 mm / 20 mm 2345161
CML720i 610/40 S+T 610 mm / 40 mm 2345162
CML720i 930/40 S+T 930 mm / 40 mm 2345163
CML720i 1250/40 S+T 1,250 mm / 40 mm 2345164
CML720i 1570/40 S+T 1,570 mm / 40 mm 2345166
CML720i 1890/40 S+T 1,890 mm / 40 mm 2345167
CML720i 2210/40 S+T 2,210 mm / 40 mm 2345169
CML720i 2530/40 S+T 2,530 mm / 40 mm 2345170
CML720i 2850/40 S+T 2,850 mm / 40 mm 2345171
Y connection cable M12 for 24 VDC and
synchronization
Order No. 2345082
0.15 m / 5 m
Cables included in light curtain module
Y connection cable M12 for CAN bus Order No. 2345083
0.25 m / 0.35 m
Cables included in light curtain module
Assembly material separate
360° swivel mount (2 items) Order No. 2345087
Encoder included in light curtain module
6.9 LIGHT CURTAIN CML720I COMPONENTS FROM 06/2014
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P_02458
P_02459
P_02460
P_02461
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
Z holder (2 items) Order No. 2345084
24 VDC eld distributor and synchronization Order No. 2345972
Field distributor, pre-assembled with 20 m cable
The eld distributor is needed if 2 - 4 light curtains
are used.
Connection cable for 24 VDC Order No. 2329743
Length 25 m
This cable is used for the voltage supply if just one
light curtain is used (e.g. height light curtain).
24 VDC eld distribution extension cable
M12 plug / coupling, PVC, 4 x 0.34; 1 m Order No. 2346047
M12 plug / coupling, PVC, 4 x 0.34; 2 m Order No. 2346048
M12 plug / coupling, PVC, 4 x 0.34; 5 m Order No. 2331620
M12 plug / coupling, PVC, 4 x 0.34; 10 m Order No. 2335391
M12 plug / coupling, PVC, 4 x 0.34; 20 m Order No. 2335393
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ProfiTech M
P_01790
P_01844
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
6.10 MOTION EQUIPMENT COMPONENTS
VU1 reciprocator
The VU1 reciprocator is suitable for use in automatic powder coating
systems with max. 16 spray guns.
The number after the designation VU1 indicates the maximum
travel in mm.
Reciprocator VU1-1800 Order No. 2327615
Reciprocator VU1-2400 Order No. 2327616
Reciprocator VU1-3000 Order No. 2327617
HU1 sliding table
Sliding table suitable for positioning a reciprocator in automatic
powder coating systems.
The number after the HU1 designation speci es the maximum
displacement in mm.
HU1-600 sliding table Order No. 2327619
HU1-1000 sliding table Order No. 2335048
HU1-1200 sliding table Order No. 2327621
HU1-1600 sliding table Order No. 2327622
Protection door
SFM 2 protection door module Order No. 2342292
Door switch PSENcode complete Order No. 2333441
Bridging plug Order No. 2342305
M12 bushing/plug straight 8 x 0.25; 2m Order No. 2333387
M12 bushing/plug straight 8 x 0.25; 5m Order No. 2333388
M12 bushing/plug straight 8 x 0.25; 10m Order No. 2333389
M12 bushing/plug straight 8 x 0.25; 20m Order No. 2333390
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6.11 MISCELLANEOUS
Ensure that the following small components pictured are not lost.
Small components:
For the assembly of the mechanical components and to connect
electric cables and the like.
System-dependent, consisting of:
screws, nuts, connections, end sleeves etc.
Grounding cable for potential equalization:
Per meter, 16 mm² Order No. 3058460
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6.12.1 MCM MASTER CONTROL
Type: Pro Tech M
Serial number: see type plate
Year of construction: see type plate
Supply: 24 VDC / 1 A
Power: maximum 17 Watt
Control system: 3A fast internal
Protection class: IP 54
Hardware: Panel PC, Atom 1.6 GHz, touch screen 10.7"
Memory: Program and data on CF type 2
Software: CE6, CoDeSys, VisiWin.net
Interfaces: Ethernet, 2 x CAN open Master, USB 2.0
Real-time clock: Battery back-up 3 V lithium button cell CR 2032
Operation: EMERGENCY STOP, main switch, illuminated push-button, key switch,
rotary controller with push button, touch screen, USB plug
Dimensions:
Width: 580 mm; 22.83 inches
Height: 360 mm; 14.17 inches without cable connections
Depth: 170 mm; 6.69 inches
Mechanical adaptation: For round pipe 40 mm; 1.57 inches
Weight:
Ambient conditions:
Operating temperature range: 5 – 45 °C; 41 – 113 °F
6.12 TECHNICAL DATA
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6.12.2 MCM CPS I/O CONTROL
Type: Pro Tech M
Serial number: see type plate
Year of construction: see type plate
Supply: 3L/PEN 230/400 V 50 Hz/60 Hz
Power consumption: maximum 5.1 kW
Fuse: 35 A
Supply line: maximum 5 x 10 mm² AWG 7
Main switch: 3-pin, N and PE, 11.5 kW
Protection class: IP 54 if not used connections are closed
Power supply unit: 24 VDC 5A / 120 W
Output 1: 2 motion groups, F3A and F4A per C25 A control system
Output 2: 2 EPG S2 Groups, F2A and F2B per D10 A control system
Dimensions:
Width: 600 mm; 23.62 inches
Height: 380 mm; 14.96 inches (only housing, without cable entries)
Depth: 210 mm; 8.27 inches
Weight:
Ambient conditions:
Operating temperature range: 5 – 45 °C; 41 – 113 °F
Conformity: CE and UL
All electrical parts, connecting terminal and stranded wires are UL
listed or recognized
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6.12.3 TECHNICAL DATA FOR MAXIMUM PROFITECH M CONFIGURATION
4 x HU1 sliding tables, 250W each Sliding table 2 groups with tow units each
4 x VU1 reciprocators, 750W each Reciprocators, 2 groups with two units each
16 EPG-S2 control units, 60W each 16 EPG S2 control units = 32 spray guns (PEA-C2; -C3; -C4; -C4 XL)
2 groups with 8 units each (maximum 8 units per group)
2 x EPG-Sprint power supply units
3 x light curtains 3 light curtain portals with Kontur 2, with Quattro CAN Open
4 x light curtains CML 720 light curtains, 3 times for the portal, 1 time for code catching
11 x digital inputs Digital inputs via CAN module for recipe selection
1 x encoder Quadrature encoder input from conveyor
EMERGENCY STOP Safety switching device for 2 EMERGENCY STOP, re extinguishing
system and external safety switching device
Powder center Interface to the powder center, 3 digital inputs, 2 digital outputs
Booth control Interface to the booth control, 1 digital input, 5 digital outputs,
2 NOC safety contacts, 2 inputs for the NOC outgoing air sensor
(low pressure)
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6.12.4 RACK 10 EPG S2
Dimensions:
Width: 500 mm; 19.69 inches
Height: 2,200 mm; 86.62 inches
Depth: 660 mm; 26 inches
Weight: approx. 150 kg; 330.68 lb
(if equipped with 10 EPG S2)
6.12.5 EPG S2
Dimensions:
Height 136 mm; 5.35 inches
Width 270 mm; 10.63 inches
Depth (without operating elements) 200 mm; 7.87 inches
Weight 5.5 kg; 12.13 lbs
Electrical:
Mains (AC) 90 VAC – 250 VAC
Frequency 47 Hz – 63 Hz
Input power maximum 60 W
Output voltage 2x maximum 22 Vpp
Output current 2x maximum 0.9 A
High-voltage 2x 10-100 kV (adjustable in 1 kV steps)
Corona current limitation 5 μA - 120 μA (adjustable in 1 μA steps)
Tribo current measurement 0 μA - 5 μA (resolution 0.5 μA)
Tribo current limitation 0 μA - 5 μA (adjustable in 0.1 μA steps)
Tribo current cut o greater than 12 μA
(ATEX: switching o of the unit)
Protection class IP 64
Ex zone II 3(2)D 80 °C; 176 °F
Pneumatic:
Air input pressure 0.6 – 0.8 MPa; 6 – 8 bar; 87 – 116 psi
Air volume maximum 30 m³/h
Sum of dosing and feed air 2 – 6 m³/h
Gun air 0.05 – 4.0 m³/h
Required compressed air quality as per
ISO8573.1
3.5.2
Connection hose diameter 8 mm; 0.315 inches
Ambient conditions:
Operating temperature range 5 – 45 °C; 41 – 113 °F
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6.12.6 EPGSPRINT X
Dimensions:
Height 136 mm; 5.35 inches
Width 270 mm; 10.63 inches
Depth (without operating elements) 200 mm; 7.87 inches
Weight 3.3 kg; 7.28 lbs
Electrical:
Mains (AC) 85 VAC – 250 VAC
Frequency 47 Hz – 440 Hz
Input power maximum 40 W
Output voltage maximum 22 Vpp
Output current maximum 0.9 A
High-voltage 10-100 kV (adjustable in 1 kV steps)
Corona current limitation 5 μA - 120 μA (adjustable in 1 μA steps)
Tribo current measurement 0 μA - 5 μA (resolution 0.5 μA)
Tribo current limitation 0 μA - 5 μA (adjustable in 0.1 μA steps)
Tribo current cut o greater than 12 μA
(ATEX: switching o of the unit)
Protection class IP 64
Ex zone II 3(2)D 80 °C; 176 °F (Zone 22)
Pneumatic:
Air input pressure 0.6 – 0.8 MPa; 6 – 8 bar; 87 – 116 psi
Air volume maximum 15 m³/h
Sum of dosing and feed air 1 – 6 m³/h
Gun air 0.05 – 4.0 m³/h
Required compressed air quality as per ISO8573.1 3.5.2
Connection hose diameter 8 mm; 0.315 inches
Ambient conditions:
Operating temperature range 5 – 45 °C; 41 – 113 °F
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Ambient conditions:
If low-melting powders are used, the ambient temperature may have to be lower than
30 °C; 86 °F.
Volume measures:
for volumes speci ed in Nm³ (standard cubic meters). One cubic meter of a gas at 0 °C and
1.013 bar is called norm cubic meter.
HINT
Compressed air quality, accessories
Danger of damage to the device.
Operate the control unit only with the prescribed compressed air quality.
Only use the control unit with original Wagner accessories.
Non-observance of these conditions results in the warranty expiring!
Outgoing air containing oil!
Risk of poisoning if inhaled.
Provide compressed air free from oil and water
(Quality Standard 3.5.2 according to ISO 8573.1)
3.5.2 = 5 μm / +7 °C; 44.6 °F / 0.1 mg/m³.
WARNING
6.13 COMPRESSED AIR QUALITY
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ProfiTech M
1
2
3
4
5
6
7
8
P_01942
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
6.14 OPERATING ELEMENTS ON THE MASTER MODULE
1 PC controller with 10.4" / 26.4 cm screen and touch operation
2 EMERGENCY STOP button
System's safety stop button
3 Display "Fault"
Lights up red in the event of a malfunction
Fault acknowledgement and safety relay start button
4 ON/OFF switch for the PC controller and EPG S2
5 "System release" display
Lights up green when the system is ON
System OFF button
6 Key switch for system release
Rotary movement to the right, with spring return
7 Rotary controller with button
for selecting and changing the setting values
8 USB connection for memory medium
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ProfiTech M
P_01487
A
B
S2
EPG
654312456
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
6.15 DISPLAY ELEMENTS FRONT SIDE OF EPG S2
1 LED display: "Operating Voltage"
The LED lights up green when the operating voltage is activated
2 LED display: "CAN Data Communication"
LED ashes/lights up green during the data communication with the master
3 LED display: "Release"
The LED lights up green when enabling has taken place
4 LED display: "Air"
The LED lights up green when the air module is activated
5 LED display: "High-voltage"
The LED lights up green when the high-voltage is activated
6 LED display: "Warning/Malfunction"
The LED ashes in the event of a warning and lights up red in the event of a
malfunction
Displays 4 - 6 exist for both gun A and gun B.
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7 ASSEMBLY AND COMMISSIONING
7.1 TRAINING THE ASSEMBLY STAFF
Incorrect installation/operation!
Risk of injury and damage to the device.
The assembly sta must have all of the technical skills to safely
undertake commissioning.
When assembling and for all work, read and follow the operating
manual and safety regulations for the additionally required
system components.
WARNING
7.2 STORAGE CONDITIONS
Until the point of assembly, the control components must be stored in a dry location, free
from vibrations and with a minimum of dust. The control components gun must be stored
in closed rooms.
The air temperature at the storage location must be between +5 °C and +45 °C; +41 and
+113 °F.
The relative air humidity at the storage location must not exceed 75%.
7.3 INSTALLATION CONDITIONS
The air temperature at the installation site must be between 5 °C and 45°C; 41 °F and
113°F.
Depending on the powder lacquer used, the maximum permissible ambient temperature
for reliable operation can be signi cantly below 40 °C; 104 °F.
The relative air humidity at the assembly location must not exceed 75%.
A skilled person must check to ensure that the device is in a reliable state after it is installed
and commissioned.
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7.4 ASSEMBLY OF THE PROFITECH M COMPONENTS
The following is a typical assembly procedure in described in broad terms. Details
regarding installation, connection and commissioning of individual devices are listed in
further chapters.
The complexity can vary depending on the scope of the assembly and the components to
be assembled.
The order, in particular the insertion of the components in the installation site can be
adapted to the existing conditions.
1. Bring all components to the installation site and organize them for quick access.
2. Assemble the powder booth and level it out.
3. Cyclone, assemble nal lter and pipe.
4. Assemble the control cabinet for the recovery unit.
5. Mount the control cabinet CPS I/O on the frame or on the intended holder.
6. Mount the MCM at the intended position, in general on the manual coating platform.
7. Assemble RS 8 roller base or electrical HU sliding table and VU reciprocator.
8. Lay out the cable racks for laying the hoses and cables.
9. Set up gun arrangement.
10. Set mechanical stops on the HU sliding table (if available) and measure the resulting
maximum displacement. -> Enter the parameters in the MCM.
11. Set the VU reciprocators' mechanical stops and measure the resulting maximum
stroke. -> Enter the parameters in the MCM.
12. Move the HU reciprocator and lifting slide by hand into all possible positions in
order to ensure that there are no collisions.
13. If a an electrical HU sliding table is used, screw the VU reciprocator's oor plate to
the HU sliding table's toothed belt carrier.
14. Connect the CPS I/O with the accompanying cable set with the MCM.
15. Connect motion technique and CPS I/O booth to the power and bus cables.
For this purpose, loop through the rst device to the next device.
16. Mount external main switch at an appropriate location.
17. Connect the CPS I/O booth to the booth cabinet via the external main switch.
18. Mount light curtain and conveyor impulse generator and connect to the CPS I/O
booth.
19. Electrically connect the powder supply system and connect it to the CPS I/O booth.
20. Ground the entire system.
21. Lay the air and powder hoses.
22. Balance the reciprocator with counterweights.
23. Set parameters on the frequency converters (address, baud rate on the electrical
devices) as well as the terminating resistor on the CAN bus loop's last device.
24. Lay the interlock with the other components (conveyor, re protection, etc.).
25. Have the complete electrical installation checked by quali ed personnel.
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ProfiTech M
P_01949
OPERATING MANUAL
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7.5 SETTING UP THE RACK
Fastening holes
Danger of tipping!
Risk of injury and damage to the device.
Secure the rack against tipping during transport.
Screw rack to base at the fastening holes at the installation site.
WARNING
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2 3 4 51 6
7 8 9 10 1211 13 14 15
P_01943
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.6.1 CPS CONTROL CABINET DESIGN
1 Safety fuse for 24 VDC departures at X12 and X30 terminal blocks
2 Multifunctional module MCM I/O unit, Order No. 2330003
3 Universal power supply 220 V±20% / 24 VDC, 5 A for supplying the control system
4 Pilz safety switching device, Order No. 2325207
5 Safety protection for the secure separation of the motion technique's power supply
6 Circuit breaker for motion, EGP S2 and control system
7 Push-in connector for 4 CAN buses, 2 EPG-Sprint Xs and 1 conveyor encoder
8 X10 terminal block for light barriers
9 X12 terminal block for external emergency stop button
10 X13 terminal block for conveyor technology and system OK
11 X20 terminal block for powder center
13 X21 terminal block for booth control cabinet
14 X30 terminal block for motion technique
15 X30 terminal block for EPG S2 group supply with AC
16 X40 terminal block 10 mm² for AC supply input L1, L2, L3, N, PE
7.6 SYSTEM DESCRIPTION
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7.6.2 TERMINAL DESCRIPTIONS
Signals for security technology:
To obtain/achieve/reach SIL2, both channels 1 and 2 must always be connected.
All signals which are highlighted in grey are security-related.
X10 terminal block for light barriers
Function Signal Terminal strip Clamps Contact /Signal type
Operating voltage for light barrier +24 VDC X10 1 +24 VDC fuse FS 1
Light barrier signal Digital IN X10 2 Digital input 24 VDC
GND for inputs GND X10 3 GND
X12 terminal block for external EMERGENCY STOP button
Function Signal Terminal strip Clamps Contact /Signal type
EMERGENCY STOP, external Channel 1 X12 1 and 2 Potential-free NCC
EMERGENCY STOP, external Channel 2 X12 3 and 4 Potential-free NCC
X13 terminal block for conveyor technology and system OK
Function Signal Terminal strip Clamps Contact /Signal type
Safety switching device, external Channel 1 ON X13 1 and 2 Potential-free NOC
Safety switching device, external Channel 2 ON X13 3 and 4 Potential-free NOC
Safety switching device, external Channel 1 OFF X13 5 and 6 Potential-free NOC
Safety switching device, external Channel 2 OFF X13 7 and 8 Potential-free NOC
System I/O * Contact X13 9 and 10 Potential-free NOC
Conveyor operating Digital IN X13 11 Digital input 24 VDC
Auxiliary voltage for input +24 VDC X13 12 +24 VDC from FS1
* Relay output: System OK
Switching status (contact closed):
If all these conditions are satis ed:
- Controller runs (is powered and is started up)
- Emergency stop circuit started
- The MCM does not have a "System stop" error
Idle status (contact open):
- As soon as one of the above conditions is not satis ed
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X20 terminal block for powder center signal including EMERGENCY STOP
Function Signal Terminal strip Clamps Contact /Signal type
EMERGENCY STOP from
Powder Center
Channel 1 X20 1 and 2 Potential-free NCC
EMERGENCY STOP from
Powder Center
Channel 2 X20 3 and 4 Potential-free NCC
EMERGENCY STOP
transmission to PC
Channel 1 X20 5 and 6 Potential-free NOC
EMERGENCY STOP
transmission to PC
Channel 2 X20 7 and 8 Potential-free NOC
Outgoing air OK for Powder
Center
Contact X20 9 and 10 Potential-free NOC
Auxiliary voltage for inputs +24 VDC X20 11 +24 VDC from I/O Module
Powder center OK Digital IN X20 12 Digital input 24VDC/3.3 mA
Request PC cleaning Digital IN X20 13 Digital input 24VDC/3.3 mA
Start PC inside cleaning Digital IN X20 14 Digital input 24VDC/3.3 mA
Cleaning ready at PC Digital OUT X20 15 Digital output 24VDC/100 mA
Cleaning preparation PC Digital OUT X20 16 Digital output 24VDC/100 mA
GND for inputs and outputs GND X20 17 GND
X21 terminal block for booth control cabinet
Function Signal Terminal strip Clamps Contact /Signal type
Fire alarm Channel 1 X21 1 and 2 Potential-free NCC
Fire alarm Channel 2 X21 3 and 4 Potential-free NCC
EMERGENCY STOP
transmission to booth
control cabinet
Channel 1 X21 5 and 6 Potential-free NOC
EMERGENCY STOP
transmission to booth
control cabinet
Channel 2 X21 7 and 8 Potential-free NOC
Outgoing air OK for EPG S2 Contact X21 9 and 10 Potential-free NOC
Outgoing air OK for Powder
Center
Contact X21 11 and 12 Potential-free NOC
Ventilator 1 START/STOP Digital OUT X21 13 Digital output 24VDC/100 mA
Ventilator 2 (20 Hz Eco) Digital OUT X21 14 Digital output 24VDC/100 mA
Ventilator 3 (40 Hz normal) Digital OUT X21 15 Digital output 24VDC/100 mA
Booth light ON/OFF Digital OUT X21 16 Digital output 24VDC/100 mA
Booth cleaning ON/OFF Digital OUT X21 17 Digital output 24VDC/100 mA
Ventilator is running Digital IN X21 18 Digital input 24VDC/3.3 mA
Outgoing air OK
24 VDC Signal
Digital IN X21 19 Digital input 24VDC/3.3 mA
GND for inputs and outputs GND X21 20 GND
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X30 terminal block for motion technique and EPG-S2 supply
Function Signal Terminal strip Clamps Contact /Signal type
Motion group 1 DC+ +24 VDC X30 1 +24 VDC fuse 1.6AT FS2
Motion group 1 DC_GND GND X30 2 GND
Motion group 1 AC 230 VAC X30 3 Phase fuse C25A F3A
Motion group 1 AC Neutral X30 4 Neutral conductor
Motion group 1 AC Earth X30 5 Grounding connection
Motion group 2 DC+ +24 VDC X30 6 +24 VDC fuse 1.6 AT FS2
Motion group 2 DC_GND GND X30 7 GND
Motion group 2 AC 230 VAC X30 8 Phase fuse C25A F3B
Motion group 2 AC Neutral X30 9 Neutral conductor
Motion group 2 AC Earth X30 10 Grounding connection
EPG group 1 AC Earth X30 11 Grounding connection
EPG group 1 AC 230 VAC X30 12 Phase D10A F2A Q3/1
EPG group 1 AC Neutral X30 13 Neutral conductor
EPG group 2 AC Earth X30 14 Grounding connection
EPG group 2 AC 230 VAC X30 15 Phase D10A F2B Q3/2
EPG group 2 AC Neutral X30 16 Neutral conductor
A maximum of two reciprocators and two sliding tables can be connected to a motion group.
This group's supply is controlled by the security switching device.
A maximum of 10 EPG-S2/EPG-Sprint X can be connected to an EPG group.
This group's supply is controlled by the K3 protection.
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7.6.3 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
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
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OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.7 CONNECTING THE MCM MODULE
MCM Master Control, Order No. 2330000
MCM CPS I/O Control, Order No. 2330001
Cable set 10 m; 32.81 ft., Order No. 2330002
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ProfiTech M
P_01952
P_01953
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.7.1 CONNECTIONS ON THE MCM MASTER CONTROL
24 VDC CAN bus
Signals 16-pin
Cable entry
7.7.2 CONNECTIONS ON THE MCM CPS I/O CONTROL
24 VDCCAN bus
Signals 16-pin
Cable entry
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ProfiTech M
P_01954
P_01955
P_01956
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
Cable entry on the MCM CPS I/O Control
For tailored cables with plugs, use separated cable
entries.
3x cable set
4x CAN bus cable
2x EPG-Sprint X
1x conveyor encoder
Close holes which are not used!
7.7.3 CONNECTION POINT FOR CAN BUS, EPGSPRINT X AND ENCODER
= light curtain
= motion technique
= EPG S2
= external extension
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ProfiTech M
P_01901
P_01950
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.8 CONNECTIONS IN THE RACK
Connect spray guns.
see Chapters 7.9 – 7.10
Connection cables:
see Chapters 6.4 – 6.11
Connect ground wire to EPG S2 and to
signal ground.
Connect supply voltage cable (Order
No.360263) to the clamp strip = E2-X2 in
the control cabinet.
Connect control voltage cable to the
terminal strip = E2-X3 in the control
cabinet.
Connect compressed air on site (0.6-0.8 MPa;
6-8 bar; 87-116 psi) to solenoid valve.
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ProfiTech M
BA
AABB
P_01490
BA
BA
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.9 CONNECTING THE AUTOMATIC SPRAY GUNS ON THE EPG S2
Tribo spray gun* Corona spray gun
Mains input
terminal
Signal ground
e.g., from the powder tank
Powder injector
Mains output to
next control unit
Atomizing air
* A Y distributor is needed to divide the di erent types of air (order no. 9990149)
e.g., from the powder tank
Powder injector
Compressed air inlet
CAN bus input
CAN bus output
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ProfiTech M
P_01745
I
O
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.10 CONNECTING THE MANUAL GUNS TO THE EPGSPRINT X
Mains input
terminal
Grounding cable to the signal ground
e.g., from the powder tank
Compressed air main
supply
(0.6 – 0.8 MPa; 6 – 8bar;
87 – 116 psi)
Hose diameter:
8 mm; 0.315 inches
Powder injector
Dosing air, blue
Feed air, red
Powder feed, transparent
Atomizing or Tribo air,
transparent
Electrical connection cable
Corona or Tribo spray gun
EPG-SPRINT X
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ProfiTech M
P_02179 P_02180
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.10.1 SIGNALS ON THE EPGSPRINT X
A maximum of two EPG Sprint X for manual guns can be connected.
This connection makes the release and ush function available.
The connection takes place with the connection cable (Order No. 2335605).
This cable can also be used to lengthen an identical cable in 10m; 32.81 ft increments.
7.10.2 PARAMETER SETTING ON THE EPGSPRINT X
For the control of the manual guns, the C26 parameter "Operating mode for manual gun
with external control" must be set in the con guration menu to value "1" or "2".
In case of replacing the control unit this parameter must be set again on the new control
unit.
The parameter and the entry into the con guration menu are described in the service
manual of the EPG-Sprint X control unit.
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P_02181
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.11 POWER SUPPLY OF THE EPG CONTROL UNITS
The power supply 230 VAC for the EPG S2 takes place via the X30 clamps: 11-13 (EPG 1) and
X30: 14-16 (EPG 2).
The same clamps can be used for the supply of the EPG Sprint X.
A maximum of 10 EPG control units can be connected to a group.
The voltage on both clamps is secured via both circuit breakers F2A and F2B and switched
via relay K3.
EPG
Group 1
EPG
Group 2
Page 56
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ProfiTech M
P_01957
P_02178
P_01958
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.12 CONNECTING THE CONVEYOR ENCODER
A 100-pulse quadrature encoder (Order No. 2335582) is used and connected via an encoder
cable (Order No. 2336565).
If necessary, one or two of these cables can be used for extension.
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ProfiTech M
P_02184
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.13 CONNECTING THE LIGHT CURTAINS
7.13.1 CONNECTION DIAGRAM FOR "KONTUR 2" LIGHT CURTAINS
Connection cables "Kontur 2":
Length system-dependent
Light curtain "Kontur 2":
Length system-dependent
Connect supply voltage cable
(Order No. 3052605) to the
terminal strip X10:1 (24VDC)
and X10:3 (GND) in the
MCMCPS.
Connect the coupling on
the "LC" connection in the
MCMCPS.
Connect connection cables at
"Quattro-DP" control section.
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ProfiTech M
P_02185
P_02186
P_02187
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
The 24 VDC supply for the light curtain portal is connected to the X10 terminal block with
the connection cable (Order No. 3052606).
The CAN bus signal is connected on connection M12 "LC" in the MCM CPS.
CAN bus cables with a length of 5 m; 16.40 ft., 10 m; 32.81 ft. or 20 m; 65.62 ft can be used.
Cable coupling,
M12 (LC)
Terminal, X10:1 = 24 VDC (wire 1)
Terminal, X10:3 = GND (wire 2)
Cable plug M12
Supply 24 VDC ± 20% = 19.2 - 28.4 VDC
Maximum current 500 mA with three light curtains
Connect wire 1 to Connection G
Connect wire 2 to Connection F
Cut o grounding cable
Plug X9
Pin G +24 VDC
Pin F GND
Pin J PNP OUT
Pin H free
Pin K free
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7.13.2 INSTALLATION OF THE "KONTUR 2" LIGHT CURTAINS
NOTICE
To avoid malfunctions of the light curtains through electrostatic in uences, the following
points should be taken into account for every system!
1. Never plug in or pull connection cables at the light
curtains or the "Quattro" control section.
First switch o 24 VDC supply or remove connection box
at "Quattro" control section.
2. A brass ring can be found at the connection thread of
every light curtain.
This ring nishes level with the fastening bracket.
Ensure that the brass ring is present.
3. The metal ring of the connector must be fully screwed
onto the thread.
It is important that the plug's metal ring has contact with
the light curtain's brass ring.
4. If the thread of the light curtain is damaged, so that the
metal ring cannot be fully screwed on, the end piece of
the light curtain must be replaced.
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5. All light curtains must be connected directly with an
equipotential bonding strip from the grounding screw
via a grounding cable.
The rail is ideally fastened to the light grid portal.
A grounding cable is laid from the equipotential bonding
strip to the ground of the control cabinet.
6. Rout the grounding cable from the ground terminal
on the "Quattro" control section to the equipotential
bonding strip.
7. As the portal pro les are made of anodized aluminum,
grounding via sliding blocks is insu cient.
Connect all pro les with each other via short grounding
cables and then with the equipotential bonding strip.
8. Connect the shield of the Pro bus cable on the "Quattro"
control section to pin 3 of the green plug.
9. Additional information:
To keep the gap in the sensing eld at the feed slot as
small as possible, turn the fastening brackets of the
upper light curtains inwards.
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ProfiTech M
24V 0V 24V 0VQ
3142
X10
P_02327
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.13.3 CONNECTION DIAGRAM FOR LGS LIGHT GRID
Receiver 8 Pin Sender 4 Pin
white green yellow brown blue
Control cabinet wiring diagram
Sender:
24 V = brown X10-1
0 V = blue X10-3
Receiver:
24 V = white X10-1
0V = green X10-3
Q = yellow X10-2
Isolate unused strands!
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7.13.4 ASSEMBLY OF CML720I LIGHT CURTAINS
Please note the assembly and installation instructions provided by the manufacturer.
These can be downloaded from http://www.leuze-electronic.de.
Light curtain assembly:
Note:
No re ective surfaces, no mutual interference!
Avoid re ective surfaces near the light curtains.
Otherwise the objects may not be detected with accuracy as a result of re ection.
Ensure su cient spacing, appropriate positioning or partitioning.
Optical sensors (e.g. light curtains, light barriers etc.) must not interfere with one
another.
Avoid allowing the receivers to be exposed to strong external light (e.g. ash lamps,
direct sunlight).
This can be achieved with su cient spacing, appropriate positioning or partitioning.
1. Select the type of fastening for transmitter and receiver.
- Fastening using T groove on one side of the standard pro le.
- Fastening using swivel mount on face ends of pro le.
- Fastening using swivel / parallel holders.
2. Keep appropriate tools at hand and observe the information relating to the assembly
locations while tting the sensors.
3. Fit transmitter and receiver level and with no distortion at the same height and/or with
the same housing reference edge.
Note:
Attention!
If sensors 2 m in length or longer are tted horizontally, use an extra fastening in the
center of the sensor.
The optical surfaces of the transmitter and receiver must be parallel with one another.
The transmitter and receiver connections must be facing in the same direction.
4. Secure transmitter and receiver so that they can't twist or move.
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Fastening using swivel mount
If assembling with the BT-2R1 swivel mount (needs to be ordered separately), the sensor
can be adjusted as follows:
Slide through the vertical slots in the swivel mount's wall plate
Rotate 360° around the longitudinal axis by xing on the screw-on cone
Tilt around the depth axis
Tip through horizontal slots in the wall fastening
If fastened to the wall using the slots, the mount can be raised above the connection cap
once the screws have been unscrewed.
The mounts do not therefore have to be removed from the wall when the device is replaced.
Unscrewing the screws is su cient.
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7.13.5 CONNECTION DIAGRAM FOR CML720I LIGHT CURTAINS WITH CODE CATCHING
CAN cabling
1 Y cable M12 plug 0.25 m; bushing 0.35 m Order No. Leuze 50118185
Order No. Wagner 2345083
3 CAN bus cable M12 plug / coupling PVC 0.6 m Order No. 2320127
CAN bus cable M12 plug / coupling PVC 2 m Order No. 2320128
CAN bus cable M12 plug / coupling PVC 5 m Order No. 2320129
CAN bus cable M12 plug / coupling PVC 10 m Order No. 2320130
CAN bus cable M12 plug / coupling PUR 15 m Order No. 2328556
CAN bus cable M12 plug / coupling PUR 20 m Order No. 2328557
10 CAN bus termination 120 Ohm bushing Order No. 2338042
24 VDC and synchronization
4 Y cable Pwr & Sync M12 plug 0.15 m; bushing 5.0 m Order No. 2345082
5 Connection cable for 24 VDC 1.0 m Order No. 2346047
Connection cable for 24 VDC 2.0 m Order No. 2346048
Connection cable for 24 VDC 5.0 m Order No. 2331620
Connection cable for 24 VDC 10.0 m Order No. 2335391
Connection cable for 24 VDC 20.0 m Order No. 2335393
6 Connection cable for 24 VDC 25.0 m Order No. 2329743
7 4-way distributor M12 Order No. 2345972
8 Supply cable 24 VDC 3 x 1.5 mm² length o roll Order No. 3052606
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ProfiTech M
X
10
1
4
5
3
3
4
1
1
1
5
3
4
8
5
5
7
4
P_02462
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
TX transmitter TX transmitter
RX receiver RX receiver
RX receiver
TX transmitter
TX transmitter
RX receiver
Code catching
= bushing
= plug
= number of cable according to table
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ProfiTech M
X
10
3
4
1
1
1
5
3
4
8
5
5
7
4
P_02476
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.13.6 CONNECTION DIAGRAM FOR CML720I LIGHT CURTAINS WITHOUT CODE CATCHING
TX transmitter TX transmitter
RX receiver RX receiver
RX receiver
TX transmitter
= bushing
= plug
The meaning of the numbers is explained in Chapter 7.13.5.
= number of cable according to table
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ProfiTech M
X
3
1
4
6
P_02477
10
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.13.7 CONNECTION DIAGRAM FOR CML720I HEIGHT LIGHT CURTAINS
RX receiver
TX transmitter
= bushing
= plug
The meaning of the numbers is explained in Chapter 7.13.5.
= number of cable according to table
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P_02464
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
All the light curtain portal's components must be connected with ground.
The transmitter and receiver must be equipped with the grounding sliding block and must
be connected to the grounded portal or nearest ground via a grounding cable.
Note:
The hex socket head screw on the sliding nut must be tightened such that the red layer
of lacque is pierced and a good electrical connection is established with the light curtain
body.
7.13.8 GROUNDING OF CML720I LIGHT CURTAINS
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7.14 COMMISSIONING THE CML720I LIGHT CURTAINS
After assembly, the CML720i light curtains must be con gured and aligned.
The individual steps are described below.
Lock:
The light curtains have a lock to prevent incorrect adjustments.
The lock is active when the keys do not respond to input.
The lock can be deactivated as described below:
– Setting on the Pro Tech M panel
– Switch o the panel and restart the light curtain (power o - on)
– Unplug CAN bus cable before switching on light curtains
Light curtain con guration
Wizard AlarmMachine
Yes N o
System
Settings
Recipe editor
Cleaning
Correction
Load recipe
Preparation
Home
General Recognition Reciprocators GunsSliding table
Light curtain type
Hanger fading out [cm]
Lock on light curtain
only height light curtain
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Function keys on the light curtain display:
"
" key: for paging through active menu
"
" key: adoption of activated value
LEDs on receiver:
LED 1, green
LED 2, yellow
LED Color State Description
(in measuring operation)
1 green ON
(lit up permanently)
Measuring light curtain ready
(normal operation)
Flashing Internal error
OFF Sensor not ready
2 yellow ON
(lit up permanently)
All active beams free - with function reserve
Flashing Internal error
OFF ≥ 1 beam interrupted
(object detected)
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P_02479
P_02480
P_02481
P_02482
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
Symbol Meaning
"Input" function.
The selected radio button (with bright background) may be a xed
adjustment parameter or a multi-digit input eld.
If it's a multi-digit input eld, you can use the "Selection" key to
increase the active number by one and the "
" key to switch from
one number to the next.
"Selection con rmation" function.
This symbol appears when a radio button is ended with the "
" key.
"Reject a selection" function.
You access this symbol from the previous symbol (tick) by pressing
the "
" key.
This mode allows you to reject the current value or option parameter
by pressing the " " key.
"Return to selection menu" function.
You access this symbol from the previous "Cross" symbol by pressing
the "
" key.
This mode allows you to reset the current value or option parameter in
order to enter a new value or select an option parameter by pressing
the "
" key.
Meaning of display symbols:
LEDs on transmitter:
LED Color State Description
1 green ON
(lit up permanently)
Measuring light curtain ready
(normal operation)
OFF No communication with the receiver
There is an LED on the transmitter for displaying function.
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7.14.1 SETTING THE BAUD RATE
The baud rate must be set to 250 kBaud. The baud rate is set as described below.
Procedure:
This appears on the receiver's display when the light
curtain is switched on.
1. Press "
" key, the menu shown in the left appears.
2. Press "
" key, the "Mode" function is displayed with a
bright background.
3. Press "
" key until the "CANopen" function is
displayed with a bright background.
4. Press "
" key, the "NodeID" function is displayed with
a bright background.
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5. Press " " key, the "Baud rate" function is displayed
with a bright background.
6. Press "
" key, the set baud rate function is displayed
with a bright background.
7. Press "
" key until the desired baud rate is displayed
with a bright background.
8. Press "
" key, the "Selection con rmation" symbol is
displayed with a bright background to the left of the
baud rate.
Either the "Reject selection" function or "Return to
selection menu" function is set by pressing the "
"
key.
The set function is adopted by pressing the " " key.
9. Press "
" key, the "Back" function is displayed with a
bright background.
10. Pressing the " " key takes you back to the
superordinate menu.
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7.14.2 SETTING NODE ID
Procedure:
This appears on the receiver's display when the light
curtain is switched on.
1. Press "
" key, the menu shown in the left appears.
2. Press "
" key, the "Mode" function is displayed with a
bright background.
3. Press "
" key until the "CANopen" function is
displayed with a bright background.
4. Press "
" key, the "NodeID" function is displayed with
a bright background.
The CANopen Node ID's have to be assigned as follows.
Height of light curtain: 62
Depth 1: 63
Depth 2: 64
Code catching recipe: 65
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5. Press " " key, the set nodeID is displayed.
The numerical value with the bright background is
increased by one by pressing the "
" key.
Pressing the " " key switches to the next column of
numbers.
6. Press "
" key, the "Selection con rmation" symbol is
displayed with a bright background to the left of the
node ID.
Either the "Reject selection" function or "Return to
selection menu" function is set by pressing the "
"
key.
The set function is adopted by pressing the "
" key.
7. Press "
" key, the "NodeID" function is displayed.
8. Press "
" key until the "Back" function is displayed
with a bright background.
9. Pressing the " " key takes you back to the superordinate
menu.
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7.14.3 ALIGNMENT OPERATION
The "Alignment operation" function is used to align the light curtains to one another. This
function can be activated via the menu on the light curtain's local operating display. The
rst and last beams in the light curtain are shown as bars.
Procedure:
This appears on the receiver's display when the light
curtain is switched on.
1. Press "
" key, the menu shown in the left appears.
2. Press "
" key, the "Mode" function is displayed with a
bright background.
3. Press "
" key, the "Operation" function is displayed
with a bright background.
4. Press "
" key, the "Alignment" function is displayed
with a bright background.
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5. Press " " key, the "Selection con rmation" symbol is
displayed with a bright background to the left of the
"Alignment" eld.
Either the "Reject selection" function or "Return to
selection menu" function is set by pressing the "
"
key.
The set function is adopted by pressing the " " key.
6. Press "
" key, two bar graph elds display the
alignment status of the rst beam (FB = First Beam)
and last beam (LB = Last Beam).
Both bar graph elds must be completely lled.
7. To align the light curtains, loosen fastening screws on
transmitter and receiver and align transmitter and
receiver with one another.
8. Once aligned, retighten fastening screws of
transmitter and receiver.
9. Once the alignment operation is complete, go back
to the measurement operation.
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7.15 CONNECTION OF THE MOTION TECHNIQUE
A maximum of 4 VU1 reciprocators and 4 HU1 sliding tables can be connected to a
Pro TechM system.
A supply voltage of 230 VAC 50/60 Hz and 24 VDC is needed for the operation of the
inverter / position encoder.
To supply 230 VAC, two supply groups are provided.
They can be connected to terminal X30.
The load must always be evenly divided between the two groups.
Group 1 = line protection F3 A
Group 2 = line protection F3 B
The CAN signal for the motion technique is to be connected to the "Move" connection on
CAN 2, together with the converter, one after the other.
An M12 plug and an M12 coupling, for the transmission, are available on each converter.
The CAN bus termination must be set on the last inverter!
The SFM2 module (protection door module) can be inserted in the supply cable as an
option.
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P_2194
12345
X30
678910
2
1
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.15.1 CONNECTIONS WITH TWO MOTION UNITS
SFM2
Optional
CPS
CAN
Power 230 VAC
Switch on CAN
bus termination
Page 80
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ProfiTech M
P_02182
12345
X30
678910
2
1
4
3
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.15.2 CONNECTIONS WITH FOUR MOTION UNITS
SFM2
Optional
CPS
CAN
Power 230 VAC
Switch on CAN bus termination
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Rdcba6432168421
P_01991
P_02512
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.15.3 SETTING NODE ID'S AND BAUD RATE ON SLIDING TABLE
The CAN node ID has to be set on the sliding table's frequency converter.
The setting takes place via the DIP switch 1-64.
Setting sliding table 1: Adress 11 (DIP switch 1, 2 ,4 ON)
Setting sliding table 2: Adress 12 (DIP switch 3, 4 ON)
Further sliding tables will be consecutively numbered (13, 14; ...).
on
o
Address: 11
Baud rate: 250
Terminating resistor: OFF
The baud rate can be set with switches a to d.
The value is set to 250 KB (switch a ON) in the factory.
On the last device of the CAN loop, switch R has to be set to ON.
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Rdcba6432168421
P_01990
P_02512
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.15.4 SETTING NODE ID AND BAUD RATE ON RECIPROCATOR
The CAN node ID has to be set on the reciprocator's frequency converter.
The setting takes place via the DIP switch 1-64.
Setting reciprocator 1: Adress 21 (DIP switch 1,3,5 ON)
Setting reciprocator 2: Adress 22 (DIP switch 2, 3, 5 ON)
Further reciprocators will be consecutively numbered (23, 24; ...).
on
o
Address: 21
Baud rate: 250
Terminating resistor: OFF
The baud rate can be set with switches a to d.
The value is set to 250 KB (switch a ON) in the factory.
On the last device of the CAN loop, switch R has to be set to ON.
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P_02454
OPERATING MANUAL
VERSION 07/2014 ORDER NUMBER DOC 2335144
7.15.5 CONNECTING SPRAY GUN BLOW OUT FIXTURE
The spray gun blow out xture is controlled via the HU1 sliding table.
It must be connected before the sliding table assumes its nal position.
Fit the sliding table at a distance of 10 cm from the booth wall to provide access to the face
end for servicing.
1. Dismount front panel on sliding table.
2. Pull out cable on front with valve plug and plug valve
plug onto solenoid valve.
3. Re t front cover on sliding table.
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7.16 GROUNDING
For security reasons the Pro Tech M 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.
It is important for system's safety and to achieve an optimum coating, that all system
components such as work pieces, conveyors, paint supply, control unit and booth are
perfectly grounded.
A poorly grounded work piece causes:
dangerous electric charging of the work piece,
very poor wrap-around,
uneven coating,
back spraying to the spray gun, i.e. contamination.
Prerequisites for perfect grounding and coating are:
Clean work piece suspension.
Grounding of spray booth, conveyor system and suspension on the building side in
accordance with the operating manuals or the manufacturer's information.
Grounding of all conductive parts within the working area.
The grounding resistance of the work piece may not exceed 1 MΩ (megohm).
(Resistance to ground measured at 500 V or 1,000 V).
The footwear worn by the operators must comply with the requirements of
ENISO 20344. The measured insulation resistance must not exceed 100 MΩ (megohms).
No Grounding!
Risk of explosion and risk of electric shock.
Electrostatic control units and the associated spray equipment
may only be connected to mains supplies with a protective
conductor connection (PE conductor)!
DANGER
Heavy powder mist if grounding is insu cient!
Danger of poisoning.
Insu cient paint application quality.
Ground all device components.
Ground the work pieces to be coated.
WARNING
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The protective clothing, including gloves, must comply with the requirements of
EN ISO 1149-5. The measured insulation resistance must not exceed 100 MΩ
(megohms).
Sparks between conveyor, conveyor hooks (hangers) and work piece can occur
if electric contact points between conveyor, conveyor hooks (hangers) and work
piece are not su ciently cleaned and therefore the work pieces are not su ciently
grounded!
These sparks can cause heavy radio frequency interference (EMC).
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7.17 COMMISSIONING
Before commissioning, the entire electrical installation and the correct electrical connection
of all components are to be checked and released by an electrician.
Take enough time to carry out the individual steps calmly and carefully.
Read the entire operating manual carefully.
1. Switch on the main switch on the booth cabinet or distributor cabinet and check if
energy is correctly transferred to the other users.
2. Switch on external main switch (supply line to the CPS I/O Cabinet)
3. Switch on the MCM.
The operating system is loaded and the home screen appears after approx.
15seconds.
4. Ensure that the motion component's traveling distance is clear and that no persons
are working on the device.
5. Switch on key switch.
6. Log in to the system parameters with authorization.
7. Check if the indicator lights on the motion devices and control units for the gun
make indications correctly.
8. Call up the parameters menu on the MCM.
8. With the help of Installation Wizard, carry out all steps in the order in which they are
displayed.
10. Load a coating recipe.
11. Test the system function in manual mode.
12. Carry out coating in manual mode with the help of test work pieces (In order to to
this, the conveyor must be ready for operation.) and check the correct function of
the components.
13. Create new recipes with optimized settings for optimal coating results.
Copying an existing recipe into a new recipe and then changing the parameters is
recommended.
To optimize using the correction menu, you can temporarily change values, test the
coating results and nally save the recipe editor using the "Applied" function.
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8 OPERATION
8.1 TRAINING THE OPERATING STAFF
8.2 SAFETY INSTRUCTIONS
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.
WARNING
Incorrect operation!
Risk of injury and damage to the device.
If contact with solvent-based paints or cleaning agents causes
skin irritation, appropriate precautionary measures must be
taken, e.g. wearing protective clothing.
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.
WARNING
Note general rules when manipulating the system.
Observe safety instructions in Chapter 4.
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8.3 WORK
8.3.1 STARTING / ENDING COATING OPERATION
Ensure that:
the regular safety checks are carried out in accordance with Chapter 9.2.3,
commissioning is carried out in accordance with Chapter 7.17.
The steps for starting and ending the coating operation are described in the Pro Tech M
operating manual "Software and operation".
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9 CLEANING AND MAINTENANCE
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
9.1 CLEANING
9.1.2 SAFETY INSTRUCTIONS
9.1.1 CLEANING STAFF
Explosive powder/air mixes!
Danger to life and damage to the device.
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.
DANGER
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The cleaning 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 the safety instructions provided in Chapter 4
must be adhered to for all cleaning work.
9.1.3 CLEANING PROCEDURES
Incorrect maintenance!
Risk of injury and damage to the device.
If contact with powder products or cleaning agents causes skin
irritation, appropriate precautionary measures must be taken,
e.g., wearing protective clothing.
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.
WARNING
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9.2 MAINTENANCE
9.2.1 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 solvent vapors
- Use of unsuitable tools and aids
An authorized person must ensure that the system is checked for being in a reliable state
after maintenance work is completed.
9.2.2 SAFETY INSTRUCTIONS
Observe the safety instructions in Chapter 4 and Chapter 9.1.2.
Prior to maintenance
- Clean system Chapter 9.1.3.
After maintenance
- Carry out a safety checks in accordance with Chapter 9.2.3.
- Turn on the system.
DANGER
Incorrect maintenance/repair!
Danger to life and damage to the device.
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 and compressed air supply.
- Relieve spray gun and device pressure.
- Secure the spray gun against actuation.
Observe the operating manual and service manuals at all times
when carrying out work.
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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
per shift weekly
Blow out guns and check for sintering
Check gun settings
Check gun discharge pressure
Blow out powder hoses
Check grounding
Check compressed air quality
Check gun voltage
Check powder hoses for bends and sintering
9.2.4 MAINTENANCE PROCEDURES
Incorrect maintenance!
Risk of injury and damage to the device.
If contact with powder products or cleaning agents causes skin
irritation, appropriate precautionary measures must be taken,
e.g., wearing protective clothing.
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.
WARNING
9.2.3.1 GROUNDING CHECK
Every day
Before starting work, carry out a visual check to ensure that the system is grounded.
9.2.3 SAFETY CHECKS
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10 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 Table4.
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Section Type of inspection Requirements Inspection
by
Type of inspection Inspection
interval
1E ectiveness of technical
ventilation check
E ectiveness of technical
ventilation check
TP/SP
ME
Measurements of air ow speed /
air quantities
Check the di erential pressure
indicator.
continuously
2 Interlock between technical
ventilation and high-voltage,
compressed air and coating product
supply
The technical ventilation should
be interlocked such that the
powder feed and high-voltage
cannot be switched on, while the
technical ventilation is not working
e ectively.
CP
FI
Test whether the system is safely
stopped and the product supply,
supply air, and high-voltage
are switched o when the
ventilation is shut down.
annually
3 Parts carrying high-voltage outside
the spray area
Parts carrying high-voltage outside
the spray area must be routed such
that discharges which put people at
risk do not occur.
CP
FI
Inspect and test (e.g., by
measurement) whether all parts
carrying high-voltage do not
result in discharge which puts
people at risk.
weekly
Legend:
MA = Manufacturer
EM = Employer
CP = Capable person
FSE = Fire safety engineer
ELC = Electrician
TP = Trained person
FI = Function inspection
ME = Measurement
SI = Standard inspection
VI = Visual inspection
CI = Continuous inspection
TI = Technical inspection
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Section Type of inspection Requirements Inspection
by
Type of inspection Inspection
interval
4E ectiveness of grounding
measures
All the system's conductive
elements, such as oors, walls,
ceilings, protective grating,
transport equipment, work
pieces, powder tanks, machines or
construction parts etc. in the spray
area, with the exception of parts
which carry high-voltage during
operation, must be connected to
the grounding system. Parts of
the booth must be grounded in
accordance with EN 12215.
CP
VI/ME/CI
Visual check of ground
connections, perform function
test on grounding switch,
measurement of grounding
resistors.
weekly
5 Measures to take if conductive
components are insu ciently
grounded
If su cient grounding of
conductive parts cannot be
ensured, their discharge energy
must not exceed the permissible
value.
CP ME/CI
Measurement of discharge
energy.
weekly
6 Resistance to ground of work
piece's locating point
The resistance to ground of
every work piece's locating point
must not exceed 1 megohm
(measurement voltage must be
1,000 V). The design of the work
piece receiver must ensure that the
adapters remain grounded during
coating.
CP ME/CI
Measure resistance to ground
(work piece receiver - ground
potential)
max. 1 megohm @ 1,000 V.
weekly
Legend:
MA = Manufacturer
EM = Employer
CP = Capable person
FSE = Fire safety engineer
ELC = Electrician
TP = Trained person
FI = Function inspection
ME = Measurement
SI = Standard inspection
VI = Visual inspection
CI = Continuous inspection
TI = Technical inspection
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Section Type of inspection Requirements Inspection
by
Type of inspection Inspection
interval
7 Measures to take if the work pieces
are insu ciently grounded
If su cient work piece grounding
in accordance with section 6
cannot be ensured, appropriate
equipment, e.g., ionizers, must
be used to discharge electric
charges on the work piece. Such
equipment must not exceed the
permitted discharge energy of the
spray systems with which it is used.
In terms of permitted discharge
energy, this equipment must be
put through the same inspections
as the powder spray systems used
with it. The discharge equipment
must be interlocked with the spray
system such that the high-voltage
is switched o and that coating
cannot take place if the discharge
equipment malfunctions.
CP ME/FU/SÜ
Measurement of discharge
energy, check the monitoring
equipment's test function by
triggering it.
weekly
8E ectiveness of the manually
or automatically actuated re
extinguishing systems
(room protection system)
E ectiveness of the manually
or automatically actuated re
extinguishing systems
(room protection system).
HE/BSB FI
Trigger re extinguishing
system, observe manufacturer's
requirements.
6 months
Legend:
MA = Manufacturer
EM = Employer
CP = Capable person
FSE = Fire safety engineer
ELC = Electrician
TP = Trained person
FI = Function inspection
ME = Measurement
SI = Standard inspection
VI = Visual inspection
CI = Continuous inspection
TI = Technical inspection
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11 DISASSEMBLY AND DISPOSAL
11.1 DISASSEMBLY
WARNING
Incorrect disassembly!
Risk of injury and damage to the device.
Before starting disassembly:
- Switch o the energy/compressed air supply.
- Ensure that all system components are grounded.
- Secure system against being switched back on without
authorization.
Observe the operating manuals for any work.
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. should be removed to keep the risk of re during
disassembly as low as possible.
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 plastics
- Cable
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12 SPARE PARTS
12.1 HOW CAN SPARE PARTS BE ORDERED?
Always supply the following information to ensure delivery of the right spare part:
Order number, designation, and quantity
The quantity need not be the same as the number given in the quantity column "Stk" on
the lists. This number merely indicates how many of the respective parts are used in each
component.
The following information is also required to ensure smooth processing of your order:
Identi cation in spare parts lists
Explanation of column "K" (labeling) in the following spare parts lists.
- Billing address
- Delivery address
- Name of the person to be contacted in the event of any queries
- Type of delivery (normal mail, express delivery, air freight, courier etc.)
= Wearing parts
Note: These parts are not covered by warranty terms
= Not part of the standard equipment but available as a special accessory.
Incorrect maintenance/repair!
Risk of injury and damage to the device.
Repairs and part replacement may only be carried out by
specially trained sta or a WAGNER service center.
Before all work on the device and in the event of work interruptions:
- Switch o the energy/compressed air supply.
- Ensure that all system components are grounded.
- Secure the device against being switched back on without
authorization.
Observe the operating and service manual at all times when
carrying out work!
WARNING
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12.2 SPARE PARTS RECOMMENDATION FOR THE CONTROL CABINET
The parts list of the electric circuit diagram lists all control cabinet components.
Light curtains or frequency converters are order-related.
Priority 1:
Components that must be on the spare parts list.
Priority 2:
Components that are recommended for the spare parts list.
Priority 3:
List of all other components, that are not necessarily recommended for the spare parts list.
Order No. Stk Designation Priority
2330000 1 MCM Master Control
2330001 1 MCM CPS I/O Control
2330002 MCM cable set, 10m
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13 EXTENDED OPERATING MANUAL
Depending on the system equipment, the following operating manuals are required to
operate the entire system.
This extended operating manual includes:
Give important information required for the connection and commissioning of the
respective component.
Give important information required for the use (e.g., change of paint) of the respective
component.
The very important chapter "Maintenance and cleaning" for the relevant components.
The description of troubleshooting and error correction for the respective components
and
a list of spare parts, wearing parts and accessories.
Operating manual Order No. Language
EPG S2 control unit 2317573 German
2317574 English
2317575 French
2317576 Italian
2317577 Spanish
EPG-Sprint X control unit 2327591 German
2329371 English
2330847 French
2330848 Italian
2330849 Spanish
PI-P1/PI-F1 powder injector 241890 German
241891 English
241892 French
241893 Italian
241897 Spanish
Hicoat ED-Pump powder injector 241885 German
241886 English
241887 French
241888 Italian
241889 Spanish
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