User manual
Contents
1. C 0080 Il2D ISSePO4ATEX119 A MMV TA il EEx 2 m Ce 0080 120 When configured iov ISSePOAATEX1 19 according to 800000045 EEx 2 mJ When configured ROVED Sann es according to 800000045 AUTO MACH JET C5 Sames o wee Meylan France AUTO MACH JET FCC For Electro Fin Appl CL II Spray Matl P N 1527015 Meylan France o L N ADU For Electro Fin Appl CL II Spray Mat o LLI a FCC Auto Mach Jet Auto Mach Jet DES02913 4 CRN457 B d 1523297 Meylan f Franco EN 50050 0080 EN 1 2 D ISSePO4ATEX119 EEx2mJ IP20 190 270V 50 60Hz 60VA U output 40V rms output 400mA rms IP input 741 bar CRN 457 control module 1 2 Safety Regulations This equipment may be dangerous if it is not used in compliance with the security regulations specified in this manual The CRN 457 electro pneumatic control module must never be installed where there is a risk of explosion The electrostatic paint spraying equipment must only be used by qualified personnel fully informed of rules no 1 to 12 as follows A warning notice written in a language understood by the operator summarising safety regulations nos 2 to 9 section 1 2 of this manual must be placed in a clearly visible position close to the powder spraying booth Shoes intended for operator use must be anti static and comply with the ISO 2251 publication If gloves are used only anti static gloves or gl2. J E Unit First Consii Item P N Description Qty of Emer aba sale gency 1527001 Plug and cable assembly 1 1 1 Q2HRDC166 Spring 1 1 2 J2CTPB457 O ring PB 701 1 1 E Index revision E 40 6366 10 5 Counter electrode assembly Ref 1527017 ZZ Zz EA 5 a Unit First Consi Item P N Description Qty of Emer male sale gency 1527017 Counter electrode assembly 1 1 1 J2CTPB324 O ring PB 701 1 1 X 2 1412251 Counter electrode conductor seal 1 1 X 3 1412252 Counter electrode insulating seal 1 1 X 4 1527023 Counter electrode cable assembly 1 1 X Index revision E 41 6366 10 6 Nozzles 10 6 1 Fan spray nozzle Ref 1525492 DES02720 Unit First Sons Item P N Description Qty of Emer mable sale gency 1 1525492 Fan spray nozzle assembly without deflector 1 1 X 2 1412250 Conductor O ring included in item 1 1 1 X 1313519 Medium fan spray deflector white Option 1 or 10 X 3 1311409 Narrow fan spray deflector light grey Option 1 or 10 X 1311793 Wide fan spray deflector red Option 1 or 10 X 1315957 Standard fan spray deflector yellow 1 1 or 10 X 10 6 2 Round spray nozzle Ref 1525493 i Unit First Consu Item P N Description Qty of Emer mable sale gency 1 1525493 Round spray
3. Values are given for a temperature of 0 C 32 F at an atmospheric pressure of 1 013 mbar WARNING Non compliance with these characteristics may result in incorrect operation of the CRN 457 control module WARNING A 5um filter must be installed upstream of the CRN 457 control module compressed air supply system The size of this filter depends on the size of the installation Sames Technologies advises to use a filter like the one indicated in section see S 10 7 1 page 44 If any damage on the equipment happens because of a polluted air the warranty could be not applied Index revision E 9 6366 4 Operation The Auto Mach Jet spray gun is connected to the CRN 457 control module This module provides the low voltage high frequency power supply required for operation of the spray gun s high voltage current generator The CRN 457 control module may operate in either local or remote mode In local mode The operator has access to various screens The CRN 457 control module includes the facilities for adjusting displaying and monitoring the high voltage current of the spray gun Methods for modifying or adjusting settings are described in the following chapters Note if a PLC is connected to the CRN 457 control module the operator has 10 seconds to take control of local mode on display of screen A Every minute a key any key must be pressed in screen A in order to maintain local mode
4. 1526284 Front of CRN 2 cabinet 1 1 1526286 Front of CRN 1 cabinet 1 1 z Unit First Const Item P N Description Qty of Emer mabla sale gency 910000092 CRN 457 PLC Connection cable 1 1 B E4PTFS572 Male PLC plug 19 contacts 1 1 E4PTFD574 Crimp contact 18 1 E Plug specific tools W6EDEM089 Removal tool sprayer plug WGEDEMO90 Removal tool PLC plug 44 Index revision E 6366 Manual flush filter Unit First Cancun ltem P N Description Qty of Emer able sale gency R4DFCM199 Manual flush filter 1 1 F6ERLCS204 Male union 2 1 R4DACC200 Filter cartridge 1 X X3AVSY119 Screw Chc M4 x12 steel 8 8 zinc D 1 i plated X2BDMU004 Washer M4 U zinc plated steel 2 1 10 7 2 Items for FCC Auto Mach Jet i Unit First Gansu ltem P N Description Qty of Emer mable sale gency 1204441 Orthogonal fixing nut 50 60 1 1 10 7 3 Items for Auto Mach Jet First Gans Item P N Description Qty of Emer mable sale gency 749805 Orthogonal fixing nut 50 30 1 1 Index revision E 45 6366 11 FM Approved Configurations HV generator molding Spray nozzle Cable length Option Guns 3 2 ogs eon 2885 ES m JP SERZ28 28 So EX Be T S9 EB aD BS ss P N 12 16 2 2 6 12 18 30 BL So EM 2 Bz Model N Drawing E
5. 39 10 4 Plug and cable assembly Ref 1527001 40 10 5 Counter electrode assembly Ref 1527017 41 lOO JNOZZIOS 5 3 ae Rtas descri die RP pu Soest eg V EA d aratri des 42 10 6 1 Fan spray nozzle Ref 1525492 42 10 6 2 Round spray nozzle Ref 1525493 42 10 6 3 Adjustable T OZZIO an aca wanen e x RC ACC CR CN eS 43 10 7 EXlra CQUIDMENT uuo ERE SEEN eee ee rex AES 44 10 71 COMMON CIGINCINS 2425 bE eA eee RG ae x dalen 44 10 7 2 Items for FCC Auto Mach Jet 45 10 7 3 Items for Auto Mach Jet 45 11 FM Approved Configurations 46 Index revision 4 1 Regulations Safety Regulations and Guarantee 1 1 Regulations The Auto Mach Jet has type A rating in accordance with standard EN50177 and the chapters concerned of EN50050 A file is open with a notified body to obtain the standard CE test certificate Compliance with directive 94 9 CE Spray gun marking and CRN 457 control module marking
6. Auto Mach Jet and CRN 457 control module AUTO MACH JET SAMES Technologies 13 Chemin de Malacher 38243 Meylan Cedex Tel 33 0 4 76 41 60 60 Fax 33 0 4 76 41 60 90 www sames com Index revision E 1 6366 All communication or reproduction of this document in any form whatsoever and all use or communication of its contents are forbidden without express written authorisation from SAMES Technologies The descriptions and characteristics contained in this document may be modified without prior warning and do not bind SAMES Technologies in any way whatsoever SAMES Technologies 2004 WARNING Sames Technologies is registered with the Department of Labour as a training institution Training courses enabling acquisition of the essential know how for implementation and maintenance of your equipment are held throughout the year A catalogue is available on request Thus from the range of training programmes proposed you can choose the type of apprenticeship or skill that corresponds to your requirements and production objectives These training courses may be held on your company premises or at the training centre at our head office in Meylan Training department Tel 33 0 4 76 41 60 04 E mail formation client sames com Index revision E 2 6366 Auto Mach Jet and CRN 457 control module 1 Regulations Safety Regulations and Guarantee I HOOUIQAUONS a 4 a oet brace RE Rae peque itd 1 2 Safety Regulati
7. In remote mode the operator can only view the various parameters The CRN 457 control module is monitored using an RS 485 serial link integrated into the PLC link connector On first use the control module recognizes whether it is connected to an automatic spray gun For this reason it is important that the operator should check that there is a strap between pins S and M on the PLC connector on front of module see 4 3 page 12 It is possible to return to the original factory setting at any time by holding down buttons 1 and 2 simultaneously during mains start up start stop switch located at the back of the control module Also on first use the following parameters must be entered trigger Parameters Factory value Minimum Maximum Hemote mode Slave index 1 1 99 Remote mode Communication speed 9600 baud 1200 baud 38 400 baud Auxiliary EV action synchronised with the 0 0 1 The communication speed is selected from the following list 1 200 2 400 4 800 9 600 14 400 18 200 and 38 400 baud Index revision E 10 6366 4 1 CRN 457 connections Pneumatic output General power supply Auxiliary valve Start stop Injection spare switch Pneumatic output Dilution Base plate B ou system Base plate PLC connector Spray gun plug Connecting spray gun plug Pins Name Color K Shield Metal shield M Current measurement White N
8. All cleaning operations must be done only with depressurized compressed air with a 2 5 bar maximum pressure a cloth or possibly a brush Never use water or solvents to clean equipment Fouling and wear of the Auto Mach Jet spray gun caused by the passage of powder vary according to operating conditions and the type of powder used For this reason the maintenance frequency indicated here is given as a guide only With a little experience of using SAMES equipment the user will be able to draw up his own maintenance schedule Nevertheless as an initial guide the following maintenance programme is recommended Frequency Action Before starting work Check the safety regulations see 1 page 5 Every 8 hours owitch off the high voltage power supply disassemble and clean the nozzle and the electrode using com pressed air Make sure that there is no accumulation of powder on the electrode Clean the powder ducts by blowing compressed air Between 40 and 60 hours of work Clean the spray gun nozzle and the deflector leaving them to soak in methyl isobutyl ketone MIBK WARNING MIBK solvent is toxic and flammable Index revision E 30 6366 9 Troubleshooting Symptoms Probable causes Remedies Check that the spray gun installation Insomecrtstallaten and connections comply with the instructions in the Safety Regulations chapters see S 1 page 5 The powder do
9. A appears immediately if the trigger is pressed If no faults are detected the operator can not access screen D The last 96 faults are recorded the 97th alters the list and deletes the 96th which is the preceding fault When a fault occurs the high voltage and powder supplies are disabled A specific screen enables identification of the fault and its number The operator confirms its recognition by validating with button 4 Index revision E 6366 6 7 1 Fault list Fault number Comment CRN 457 general fault 3 CRN 457 temperature excessive 4 High voltage action forbidden 5 CRN 457 general fault 6 CRN 457 general fault 7 ERE Eis CRN 457 general fault an 8 a cw CRN 457 general fault E 9 c a Short circuit on electrode Solenoid valve index Vi V1 to V8 10 to 18 Rt E Vx Auxiliary solenoid valve Faults 1 5 6 7 and 8 are the result of electrical power problems Switch the control module off then back on if the problem persists contact Sames Technologies Fault 3 is caused by excessive temperature inside the control module Whether the control module should reach a too excessive temperature an alarm message would be displayed on the screen So as not to disrupt production the control module keeps working The operator has to make the temperature decrease make sure as well that the temperature of the compressed air is infe
10. High voltage unit power supply Green P High voltage unit power supply Brown U CRN 457 power supply ground Yellow L Bridging with V V Bridging with L 4 2 Spray gun connections Item Name Color 1 High voltage unit power supply Brown 2 Current measurement White 3 High voltage unit power supply Green 4 CRN 457 power supply ground Yellow 5 Shield Metal shield Note A specific tool is necessary to dismantle the spray gun plug see S 10 7 1 page 44 Index revision E 11 6366 4 3 PLC plug connections Pins Name Correspondance A in B in OV in Shield in Serial Link input A out B out OV out Shield out Serial Link output Common NF NO Fault relay 0 5A 24V Bridging with S Bridging with M Recognition Shunt for the Auto Mach Jet except if the software version is higher than 2 07 24V PLC CAT A SOM M DO VZS ONW gt OV PLC PLC shield PLC link Advised connection of a serial link example with 3 CRN 457 software version gt 2 07 Sames Technologies advises using of a shielded cable P N 110000029 The 151 MO resistance is adapted to this cable 151 MO Advised connection of a 24V trigger if the serial link is not used 24V 0V equipped with a general shield linked to the U prong of the 19 prong connector At the other end of the cable t
11. Net Counter electrode assembly ON Rhead see 8 10 5 page 41 opuon 1 T 2 1204263 Nozzle nut 1 1 Standard fan spray deflector 1315957 see 10 6 1 page 42 1 1 or 10 X 4 1525492 Fan spray nozzle assembly see 1 1 X 10 6 1 page 42 5 1527002 Gun assembly see 10 2 page 38 1 1 6 1527019 FCC rear body assembly 1 1 7 1315630 Arm plug Diameter 60 mm 1 1 8 1411605 Support arm Diameter 60 mm 1 1 9 1314763 Counter electrode plug 1 1 10 1527023 Counter electrode cable assembly 1 X included in item 1 11 1527001 Plug and cable assembly see 10 4 1 1 i _ page 40 12 1527018 Powder pipe assembly see 10 3 1 1 page 39 13 J4BRNDO39 Fibre seal 4 1 14 X3GJBP092 Screw PT KA35x25 WN1411 galvanised 4 1 steel cross head 1527351 Auto Mach Jet and CRN linking cable 1 1 i _ Lg 30 m U1FGBA034 Hose EAV 12 17 opaque grey 15m m X Q6VRUBO01 Black velcro strip 1m m Index revision E 33 6366 10 1 2 Auto Mach Jet cable 18 m Ref 1527340 DES02922 Index revision E 34 6366 Unit First Con Item P N Description Qty of Emer iiia sale gency 1527340 Auto Mach Jet cable 18 m 1 1 1527295 Auto Mach Jet spray gun 1 n Counter electrode assembly ON Rhead see 8 10 5 page 41 opuon 1 7 2 1204263 Nozzle nut 1 1 Standard fan spray deflector PASSE see 10 6 1 page 42 Per
12. covering mode adapted with round or fan spray nozzles This application may require an adjustment of settings in the case of a very thick first coat of powder with appearance of eyes and large craters The current may be progressively reduced see voltage current adjustments until correct application is obtained 5uA minimum It is used for applying thick coats gt 100 um and for parts with low conductivity glass wood etc Metallic powder application adapted with round or fan spray nozzle This application can be optimised if the powder is coated the voltage can be increased to improve application performance Use of fan spray nozzles with a counter electrode The use of the counter electrode improves the appearance of the coating in the case of application of certain powders Index revision E 19 6366 6 6 Screen C It is used to modify the voltage and current settings of the characteristic selected in menus A and B 3 dette L 2 1 Voltage or current can be modified in this area The voltage or current value decreases when the flashing cursor is opposite the parame ter to be modified The voltage or current value increases when the flashing cursor is opposite the parame ter to be modified When these values have been modified the hand logo appears next to U and or It is possible to return to the original value if this is done the hand logo disappears 9 This butt
13. i alia see 10 6 1 page 42 1 A 5 1527002 Gun assembly see 10 2 page 38 1 1 6 1314763 Counter electrode plug 1 1 7 1527023 Counter electrode cable assembly 1 1 X included in item 1 8 1527070 Rear body assembly 1 1 Plug and cable assembly 2 ae see 10 4 page 40 1 10 X3GJBP092 Screw PT KA35x25 WN141 1 4 X galvanised steel cross head 11 J4BRNDO39 Fibre seal 4 1 X Powder pipe assembly 12 1527018 see 10 3 page 39 1 1 X 13 X2BDVX008 Fan washer AZ 8 DE galvanised steel 1 1 14 X9NDMMOO08 M8 nylon washer 1 1 15 X2BEHSO008 M8 U galvanised Nylstop nut 1 1 Arm Diameter 30mm LEN including items 13 14 15 l 1527351 Auto Mach Jet and CRN linking cable 1 1 Lg 30 m U1FGBA092 Hose EAV 11X15 12m m X Index revision E 37 6366 10 2 Gun assembly Ref 1527002 DES02919 Unit First Consus Item P N Description Qty of Emer alle sale gency 1527002 Gun assembly 1 1 1 J2CTCPO54 O ring PC 851 1 2 2 J2CTPB432 O ring PB 701 1 1 X 3 J2CTPC416 O ring PC 851 1 1 X Index revision E 38 6366 10 3 Powder pipe assembly Ref 1527018 DESO02918 Unit First Item P N Description Qty of Emer ee sale gency 1527018 Powder pipe assembly 1 1 X 1 J2CTPB166 O ring PB 701 2 1 X Index revision E 39 6366 10 4 Plug and cable assembly Ref 1527001
14. mm mm mm mm M M dic joa Sa ZE Li Auto Mach Jet 1527295 X X XI XI XI XI X X Auto Mach Jet FCC 1527015 DES03277 R f rence Auto Mach Jet R f rence Auto Mach Jet FCC Auto Mach Jet P N FCC Auto Mach Jet P N 18 M gt 1527340 z 30 M gt 910000100 30 M gt 1527318 R f rences des Equipements de Pulv risation Spraying pattern P N equipment JR12 JR16 JR20 JR25 Buse Nozzle 1525493 1525493 1525493 1525493 D flecteur Deflector 1411500 1409259 1409260 1411993 JP troit JP medium JP large large JP Standard narrow medium standard Buse Nozzle 1525492 1525492 1525492 1525492 D flecteur Deflector 1311409 1313519 1311793 1315957 Index revision E 46 6366
15. vann CER d deo eal deat ri ds LZ ASS On DIM coi specie t deoa meden eed oan caria sure 7 4 Adjustable nozzle LA DISasSelplyaase tenus Me dote ban wee 7 42 HOASSOITIDIV zanden tdt citas e cheat ob RECHT AD E ie de Index revision 3 7 5 Counter electrode 26 Zal DISaSSeOIply traan dri t DO e delete YU dr a io deed aas 26 ZIL ASSOCIES Ne y n C 26 LO JOWOGOPDIDO ust be E IEEE ESSERE ud 27 TO AISQSSOITIDI Veo uera Bodo Ne eoi A AT ORI UA ac hard Bande 27 FO ASS MON date er EEE ni SA CS Dr Eua Roi 27 Ths GUN assembly 2 5 2 snee drie 28 7 7 1 Disassembly 8 te A QU CUAL RECS ee CR e Dar n ur 28 Ll AAS SONON kanten Pati a a bean 28 7 8 Rear body and plug and cable assembly 29 7 0 T DISASSEMDI s eu sacs he hi e SEU de do dc e ER diee 29 TO JHOASSBlTIDIV ade up dard bes obe o oe bob edem i harde need ron 29 8 Cleaning Maintenance e 30 Os 1FOUDIESNOOUNG serres ere esses eei eem did t eef 31 10 Spare PASSES sets bennen neste de 32 10 1 Auto Mach Jet spray guns 32 10 1 1 Auto Mach Jet FCC Ref 1527318 32 10 1 2 Auto Mach Jet cable 18 m Ref 1527340 34 10 1 3 Auto Mach Jet cable 30 m Ref 910000100 36 10 2 Gun assembly Ref 1527002 38 10 3 Powder pipe assembly Ref 1527018
16. 40 C 12 Switch off the electrical supply of the CRN 457 module before connecting the atomizer Before disconnecting the atomizer extinguish switch off the power supply of the CRN 457 if not a mal function can occur WARNING This equipment is intended for spraying powder paint only 1 3 Guarantee Guarantee label During the CRN 457 control module guarantee period it is strictly forbidden to remove attempt to remove or cut the label located under module on pain of loss of guarantee Index revision E 6 6366 2 Presentation The Auto Mach Jet spray gun is an automatic spray gun intended for powder paint spraying An ionizing electrode located at the end of the spray gun is held at a higher negative electrical potential Due to the higher electrical field at the end of this electrode it creates negative gas ions These ions are used to charge the powderpaint by bombardment during its journey from the end of the spray gun to the part to be painted which is itself grounded The Auto Mach Jet spray gun is connected to a CRN 457 control module that controls both the high voltage and the powder flow rate of the spray gun to which it is connected These two indissociable elements constitute a powder coating device Pre programmed voltage and current settings are adjustable from the control module There are two types of Auto Mach Jet spray gun The FCC Auto Mach Jet which is used in a PVV booth he
17. andard nozzle 7 3 1 Disassembly Deflector To disassemble the deflector simply pull it it is not necessary to remove the nozzle nut Nozzle e Remove deflector e Unscrew the nozzle nut manually e Remove nozzle Nozzle extension replacing seal e Unscrew the M5 x 25 screws maintaining pressure on the central section located inside the nozzle extension Take out this central section e Remove the seal using a small screwdriver 7 8 2 Assembly Proceed in reverse order having first checked and cleaned the different components Replace them if necessary Nozzle extension Place the seal onto the central section Use the positioning pins to position the central section in the extension and tighten the assembly using the M5 x 25 nylon screw Index revision E 25 6366 7 4 Adjustable nozzle 7 4 1 Disassembly see S 10 6 3 page 43 e Unscrew the adjustable nozzle assembly from the spray gun by unscrewing the nozzle adjustment mounting nut e Unscrew the nozzle nut e Pull in line with the fan spray nozzle body fitted with the electrode Take the electrode out of the body by pushing the fixing cramps inwards in pairs e Unscrew the upper body while holding the lower body still Take the lower body out of the nozzle adjustment mounting nut 7 4 2 Reassembly Check the condition of the various components clean them using compressed air and replace them if necessary Insert the fitted
18. ect or deselect the spray gun itis possible to switch to Screen B The changes are validated If no parameter changes have been made for 1 s By pressing the trigger By changing screen keyboard 0 not high voltage supply of the24V 2 This button is used for selection or deselection of spray gun if HT Pressing this button displays or not this icon on the left of the screen In the presence of 24V there will be or If HT Keyboard z 1 selection or deselection of the high voltage ON OFF is possible directly on the keyboard independently of the Index revision E 6366 6 5 Screen B It is used to adjust the injection and dilution air and to select the pre set characteristics U I Dilution air is used to avoid spray pulses This adjustment also acts on powder spray speed The injection air is used to adjust powder flow rate i j hs f x jl J N zum 2 ts lt 4 ma LN en 1 This area is used to adjust the injec tion and dilution air and to select the pre set characteristics U l The operator can select the flow rate injec tion air from thirty two possible rates from O zero flow rate to 31 and adjust the dilution air from eight different settings from 0 to 7 1 su E r 1 i Reducing the dilution air slower spray and risk of puls ing DES02499 Increasing the dilution air faster s
19. es not come out The spray gun is incorrectly set Follow the instructions for making adjustments Insufficient air flow rate supplied by the compressed air circuit Check the circuit The powder carrying hose is obstructed Clean the powder carrying hose using compressed air Powder does not adhere to the part to be painted The part is not correctly grounded Ensure that the electrical resistance of the parts in relation to the ground sys tem is less than 1MQ The ionization electrode is covered in hardened paint or soiling Switch off the high voltage power sup ply then clean the electrode and ensure that the current delivered is less than 30 uA for fan spray nozzles The voltage is not sufficiently high Increase the voltage but ensure that the current does not exceed 30 uA for fan spray nozzles Abnormally high current con sumption Ground wire too close to the spray gun electrode Move the ground wire further away Index revision E 31 6366 10 Spare parts list 10 1 Auto Mach Jet spray guns 10 1 1 Auto Mach Jet FCC Ref 1527318 V mmu LY DES02921 Index revision E 32 6366 Unit First Con Item P N Description Qty of Emer iiia sale gency 1527318 FCC Auto Mach Jet 1 1 1527015 FCC Auto Mach Jet spray gun 1
20. ey X Fan spray nozzle assembly 3 PES see 10 6 1 page 42 1 5 5 1527002 Gun assembly see 10 2 page 38 1 1 6 1314763 Counter electrode plug 1 1 7 1527023 Counter electrode cable assembly 1 1 X included in item 1 8 1527070 Rear body assembly 1 1 Plug and cable assembly ib see 10 4 page 40 1 p 7 10 X3GJBP092 Screw PT KA35x25 WN1411 galvanised 4 1 X steel cross head 11 J4BRNDO39 Fibre seal 4 1 X Powder pipe assembly 12 1527018 see 8 10 3 page 39 1 1 X 13 X2BDVX008 Fan washer AZ 8 DE galvanised steel 1 1 14 X9NDMMOOS8 M8 nylon washer 1 1 15 X2BEHS008 M8 U galvanised Nylstop nut 1 1 Arm Diameter 30mm pe duse including items 13 14 15 L L 910000082 Auto Mach Jet and CRN linking cable 1 1 Lg 18m U1FGBA092 Hose EAV 11X15 12 m m X Index revision E 35 6366 10 1 3 Auto Mach Jet cable 30 m Ref 910000100 DES02922 Index revision E 36 6366 Unit First Con Item P N Description Qty of Emer silia sale gency 910000100 Auto Mach Jet cable 30 m 1 1 1527295 Auto Mach Jet spray gun 1 n Counter electrode assembly 1 1527017 see 10 5 page 41 option 1 2 1204263 Nozzle nut 1 1 Standard fan spray deflector 1315957 see 8 10 6 1 page 42 1 1 or 10 X Fan spray nozzle assembly
21. he shield has to be either linked to the cabinet ground or to the PLC ground Index revision E 12 DES03472 WARNING In order to comply with current EMC standards the PLC connection cable has to be 6366 5 Description of the control module The function of the automatic spray gun is to spray powder charged electrically by a high voltage unit built into the spray gun that delivers up to 95kV and 110uA 5 1 Functions available from control module WARNING All access to the various parameters on the various screens are only possible in local mode The control module displays use parameters and their settings which can be changed using the four buttons on the front panel Fe Lee ee N 457 control module front pane Six different menus can be accessed by the operator A choosing function tables and selection deselection of the spray gun e B adjusting injection and dilution air and selection of pre set characteristics U l e C manual adjustment voltage current e D history of faults encountered accessible only if a fault is recorded e E screen adjustment contrast etc e G computer link view Area 1 The front panel of the module has four buttons A graphic icon located above each button indicates the button s purpose Area 2 This display area indicates parameter status For example for screen A the injection air powder flow rate is at 0 the dilution air is at 3 The function table
22. lower body via the rear of the nozzle adjustment mounting nut e Hold the lower body in place and screw in the upper body Insert the electrode into the nozzle body until stop is reached Put the nozzle body in place and screw in using the nut 7 5 Counter electrode 7 5 1 Disassembly e Pull in line with the counter electrode taking care not to lose the cable 7 5 2 Assembly e Check the condition of the various components counter electrode cable and seals Replace them if necessary If replacing seals position them correctly in the two grooves provided for this purpose ensuring that the seals are not 1 inverted or transposed Position the cable item 3 in the counter electrode item 2 and insert it into its housing on the spray gun item 2 nstall the counter electrode on the projector and push hard DES03021 WARNING When the counter electrode is not used a plug See 10 1 2 page 34 item 6 is put into the body in the cable housing Index revision E 26 6366 7 6 Powder pipe 7 6 1 Disassembly e Start unscrewing the powder pipe using a 19 mm ring wrench and then continue manually WARNING This wrench is required otherwise there is a risk of damaging the material of the powder pipe e Remove the powder pipe from the spray gun 7 6 2 Assembly Clean the interior of the powder pipe with compressed air Check the state of the seals and the powder pipe Replace
23. nd This appears on the screen 23 6366 6 9 Screen G At this stage it is only used to view the configuration parameters 1 This button is used to switch to the next menu If no action is taken the display switches automatically after one minute to screen A dic LN i 4l d Screen A appears immediately if the trigger is pressed Index revision E 24 6366 7 Maintenance WARNING Switch off the electrical supply of the CRN 457 module before connecting the ato mizer Before disconnecting the atomizer extinguish switch off the power supply of the CRN 457 if not a malfunction can occur 7 1 Removing the FCC Auto Mach Jet spray gun from its support arm Disconnect the powder supply hose by unclipping the quick connector e Unscrew the electrical connector Pull out the plug then pass the cable and the powder hose through the slots of the plug e Unscrew the spray gun from its support 7 2 Removing the Auto Mach Jet spray gun from its support arm Disconnect the powder supply hose by unclipping the quick connector e Unscrew the electrical connector e Unscrew the Nylstop nut and remove the washers fixing spray gun to support arm WARNING When fixing the spray gun to its support arm ensure that the correct order is followed in mounting the washers first the fan washer then the nylon washer see S 10 1 2 page 34 items 13 and 14 7 3 Deflector and st
24. nozzle without deflector 1 1 X 2 1412250 Conductor O ring included in item 1 1 1 X 3 J2CTPCO020 O ring PC 851 included in item 1 1 1 X 1409259 Round spray deflector Dia 16 mm white 1 1 or 10 X 4 1411500 Round spray deflector Dia 12 mm white Option 1or10 X 1409260 Round spray deflector Dia 20 mm white Option 1or10 X 1411993 Round spray deflector Dia 25 mm white Option 1 X Index revision E 42 6366 10 6 3 Adjustable nozzle DES03018 Unit First Consi Item P N Description Qty of Emer ipid sale gency 1527292 Adjustable fan spray nozzle 1 1 1 1309357 Nozzle nut 1 1 2 1309358 Fan spray nozzle body 1 1 X 3 1412255 Adjustable nozzle and electrode 1 X assembly 4 1412257 Upper body assembly 1 1 5 1412256 Lower body assembly 1 1 6 1315266 Nozzle adjustment mounting nut 1 1 Index revision E 43 6366 10 7 Extra equipment 10 7 1 Common elements 5 a 3 A Unit First Gonsi Item P N Description Qty of Emer able sale gency 1527393 Powder hose quick disconnec 1 1 tion union 1 1315559 Hose end quick connector 1 1 X 2 J2FENV160 O ring FEP 1 1 X 3 1411501 Powder connector assembly 1 1 X 4 1315394 Dual Powder hose fitting 1 1 X First Conil Item P N Description Qty of Emer able sale gency 1523297 CRN 457 control module 1 1
25. o at the top left hand side Ed enables the device to restart with factory parameters The operator is thus in a first start up situation see S 5 2 page 14 6 2 Start up screen Screen G At first start up the operator must enter this data By default the factory parameters are validated They can always be viewed but can only be changed at first start up or during a restart with factory parameters On this screen you can choose to switch high voltage and powder ever by powering an electrical input 0 24V or directly on the keyboard button number 3 screen A in this case the 24V power is no more necessary HT Keyboard 0 means that the switch is started by 0 24V electrical input HT Keyboard 1 means that the trigger is controlled from the key board key n 3 from A screen Index revision E 15 6366 6 3 Screen displayed in remote mode t lt gt Sames re Index revision E 16 6366 6 4 Main screen A This screen is used to display the operation of the spray gun The operator can use the keyboard to choose the required function table 1 This area is used to choose the required function table There are 9 different tables from 1 to 9 It is possible to change the settings of each table individually 9 This button is used to switch to the next menu DESO2511 If the trigger is pressed itis impossible to change the table itis possible to sel
26. oltage cable carefully outwards Check the position of the wires to avoid possible pinching by the rear body Push until stop is reached DES02986 WARNING To guarantee correct sealing each time the gun is disassembled change the O ring systematically see S 10 2 page 38 item 2 Tighten these screws using a torque screwdriver to a torque of 0 7 Nm Tighten the stuffing box to a torque of 3 5 Nm Index revision E 28 6366 7 8 Rear body and plug and cable assembly 7 8 1 Disassembly Follow the procedure described above see 7 7 1 page 28 Use your thumb to push on the housing of a screw inside the rear body in order to take out the plug and cable assembly Unscrew the ground wire fixing screw from the outside in order to disconnect the ground wire and to fully detach the plug assembly from the rear body 7 8 2 Reassembly Check the condition of the seal and the spring located on the plug and cable assembly see 10 4 page 40 item 1 and 2 Replace them if necessary Pass the low voltage cable through the rear body Connect the ground wire to the screw located on the plug assembly see illustration e Install the plug and cable assembly into the rear body and push it until it reaches the stop Connect the three screws Then follow the procedure described above see 7 7 2 page 28 DES03019 Index revision E 29 6366 8 Cleaning Maintenance WARNING
27. on is used to switch to the next menu The changes are validated ne f no parameter changes have been made for 1 s By pressing the trigger By changing screen If no action is taken the display switches automatically to screen A after one minute Screen A appears immediately if the trigger is pressed 2 This button pinpoints the parameter U or I to be modi fied If U is to be increased decreases automatically if positioned on the envelope curve of the characteristic see 3 1 page 8 and vice versa Note this type of U I change will be applied to all the function tables that use this single character istic Index revision E 20 6366 6 7 Screen D This screen is used to display the history of faults encountered DESDEA4S 1 The history of the most recent faults can be displayed in this area The last fault with its index 4 in this case appears on the screen The fault s age index is indi cated on the left hand side of the screen 0 Display of faults from oldest to most recent d Display of faults from most recent to oldest 2 This button is used to switch to the next menu The changes are validated If no parameter changes have been made for 1 s By pressing the trigger By changing screen If no action is taken the display switches automatically to screen A after one minute Screen
28. ons LO GUMAMOE Lis shoes Ie deb d ENRIESCNIANO Ne ee ee 3 Characteristics 3 1 General characteristics 3 2 Compressed air quality ll 4 Operation 4 1 CRN 457 connections 4 2 Spray gun connections 4 3 PLC plug connections 5 Description of the control module 5 1 Functions available from control module REE eem don quia arii ur dame pod Road rave 6 Use of the different control module menus 6 1 CRN 457 initialisation screen 6 2 Start up screen Screen G 6 3 Screen displayed in remote mode 6 4 Main screen Au uai uu we e e ed ded aV e D 5 DOIOBN B rs duos te aai ad CEE Rees oad ra doit 60 Seen 2 2433 tee ie nt ee Loh ebe eee ee stee eae BCE D PITT OZ D IUE He SE aate aa E iode en ree DO DCIGBII ES guste ea ee Sie oy uitis snee es ae os ROM OCE O a cart teatro eh os eR Ss nd 7 Maint enances ue te dite Bos cu See tee eee eee d ee 7 1 Removing the FCC Auto Mach Jet spray gun from MS SUPDOM ANN aco sca S ace ede ages tb Pop dla bos 7 2 Removing the Auto Mach Jet spray gun from its support AMM ducas de Sard eere x RC ee 7 3 Deflector and standard nozzle Leh DISaSSOmiply
29. oves ensuring grounding of the operator may be worn The floor in the area in which the operator works must be anti static ordinary bare concrete floors are anti static Index revision E 5 6366 4 Powder spraying must be carried out in front of a ventilated booth designed for the purpose Start up of the CRN 457 must be interlocked with operation of the ventilation system 5 Skin contact with or inhalation of products used with this equipment may be dangerous for personnel cf Safety sheets for products used 6 All conducting structures such as floors walls of powder spraying booths ceilings barriers parts to be painted powder distribution tank etc that are inside or near the work station and the earth terminal on the electro pneumatic control module must be electrically connected to the ground system protecting the electrical power supply 7 Parts to be painted must have a resistance in relation to the ground system that is less than or equal to 1 MO 8 Powder spraying equipment must be maintained regularly according to the manufacturer s instructions Repairs must be carried out in strict compliance with these instructions 9 Before cleaning the spray gun or carrying out any other work in the spraying area the high voltage power supply must be switched off in such a way that it can not be switched back on 10 Only SAMES original spare parts guarantee operating safety of the equipment 11 Ambient temperature must not exceed
30. pray and less pulsing A tea H l re E 1 DES02500 Pressing the buttons above also displays the following logos in a loop zl uu E al PE Pu a f 11 Use of round spray nozzles Use of fan spray nozzles Over powder coating applica tion 46 k Metallic powder application ES Use of fan spray nozzles with a counter electrode Index revision E 2 This button is used to place the flashing cursor at the parameter to be modified injection air dilution air or selection of pre set character istics U I 9 This button is used to switch to the next menu The changes are validated If no parameter changes have been made for 1 s By pressing the trigger By changing screen If no action is taken the display switches automatically to screen A after one minute Screen A appears immediately if the trigger is pressed 6366 Use of a round spray nozzle Application using a round spray nozzle improves charging of particles It gives a better wraparound effect and has better transfer efficiency The spray is very homogenous both on complex parts and simple parts Use of fan spray nozzles Application using a fan spray nozzle gives better covering and very high performance on flat parts Powder covering of cavities is facilitated The spray is very penetrating and homogenous both on complex and simple parts Application in over powder
31. rior to 40 C Fault 4 appears when the trigger is engaged on start up of the spray gun The spray gun Is rearmed by releasing the trigger and pressing it again Fault 9 appears when there is a short circuit on the electrode The spray gun is rearmed by releasing the trigger and pressing it again Faults 10 to 18 are detected when electrical power supply faults occur on the different solenoid valves if a fault of this nature occurs contact Sames Technologies Index revision E 22 6366 6 8 Screen E This is used to adjust the screen 3 lt gt Sames 1 The screen contrast can be modified in this area Pressing the buttons corresponds to Reducing contrast the screen ue becomes increasingly brighter ON Increasing contrast the screen becomes increasingly darker mer d 9 This button is used to switch to the next menu The changes are validated dia If no parameter changes have been made for 1 s By pressing the trigger By changing screen If no action is taken the display switches automatically to screen A after one minute Screen A appears immediately if the trigger is pressed display in a loop 2 This area is used to reverse the screen colour Pressing this button reverses the Either the graphics are orange Index revision E on a black background Or the graphics are black on an orange back grou
32. standard Auto Mach Jet which is used in all other cases FCC Auto Mach Jet Auto Mach Jet Index revision E 7 6366 3 Characteristics 3 1 General characteristics Auto Mach Jet Spray Gun Temperature range for use 0 to 40 C Maximum output voltage 95 kV 5 kV 10 kV Maximum output current 110 uA or 10 uA Supply pressure 7 bar 1 bar Maximum powder flow rate 24 kg hr Weight of spray gun with cable and connector 0 85 kg CRN 457 control module Power supply voltage 90 to 270V AC Frequency 50 60 Hz Maximum power 60 VA Maximum output voltage 40V effective rms Maximum output current 110 MA effective rms Maximum air flow rate injection and dilution 6 mg h Pre programmed value characteristics U kV 80 70 J AN E PER 65 0 40 4 20 mmm Lanm i O 30 70 Example of performance curve Envelope curve 110 uA Characteristics of spray gun output voltage and current e Index revision E 8 6366 3 2 Compressed air quality Required characteristics for compressed air supply according to standard NF ISO 8573 1 Maximum dew point at 6 bar 90 psi Class 4 i e x3 C 38 F Maximum particle size of solid pollutants Class 3 i e 5 um Maximum oil concentration Class 1 i e 0 01 mg mg Maximum concentration of solid pollutants Class 3 i e 5 mg m a
33. them if necessary e Install the pipe in the spray gun it locates automatically then push it in until it stops Tighten manually then continue tightening using the 19 mm ring wrench Index revision E 27 6366 7 1 Gun assembly 7 7 1 Disassembly Follow powder pipe disassembly procedure see 7 6 page 27 e Unscrew the stuffing box item 1 in order to be able to give some slack to the high voltage cable Unscrew the four screws item 2 located at the rear of the spray gun using a Philips PH1 tip screwdriver and remove the washers item 3 e Gently withdraw the gun assembly item 6 from the rear body item 4 Be careful not to pull out the three gun connection wires Unscrew the three screws item 5 manually to disconnect the gun item 6 3 AS LBS N BA O1 DES03020 WARNING When unscrewing the screws item 2 it is possible that the washers item 3 may remain in place Loosen them using a 3mm max diameter screwdriver and take them out by pushing them from the inside of the rear body Change these washers each time the screws are removed 7 7 2 Assembly Clean the gun replace it if necessary Change the gun seal making sure to position it correctly in the gun groove Connect the three power supply wires following the wiring diagram see illustration Check alignment of the three contacts Fully tighten manually without forcing e Fit the rear body to the gun pulling the low v
34. used is P9 The pre programmed characteristics are those of metallic powder application M On first use of the module the P1 function table is always displayed on screen Area 3 The bar graph located in this area shows the instant voltage and current values in graphic and digital form Area 4 A screen entitled Main appears on start up It is identified by an icon located at the top right hand side of the screen Mist If this logo appears under A in area 4 it indicates that the operator has deselected the spray gun via button 3 If this logo appears in area 4 it indicates that the generator has shut down because of a fault see ES 6 7 1 page 22 AA When the trigger is pressed this logo flashes the arrow indicates presence of high voltage at the bottom of area 4 E Alarme information Temperature too high Index revision E 13 6366 5 2 Summary e Selection of function tables is only possible if the high voltage is switched off Powder flow rate is adjustable e from the control module e from the PLC he operator can always return to the factory parameters by switching off the control module and switching it on again while holding down buttons 1 and 2 I Index revision E 14 6366 6 Use of the different control module menus 6 1 CRN 457 initialisation screen This is the first screen displayed on start up of CRN 457 gt Sames Pressing buttons 1 and 2 simultaneously until appearance of the log
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