User manual - Stjernquists
Contents
1. DES02539 ES02538 Mach Jet Spray Gun and CRN 457 control module MACH JE Digital Preselect Coating System DPCS 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 F 1 6336 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 are held throughout the year to enable users to acquire the know how essential for operating and maintaining the equipment 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 F 2 6336 Mach Jet Spray Gun and CRN 457 control module 1 Regulations Safety Regulations and2. E4PCAL459 US Main power cable 1 E4PCAL501 UK Main power cable 1 E4PTFS572 Male PLC plug 19 contacts 1 1 E4PTFD574 Crimp contact 18 1 Plug specific tools W6EDEMO89 Removal tool sprayer plug 1 W6EDEMO9O Removal tool PLC plug 1 Manual flush filter Unit First Consu P N Description Qty of Emer able sale gency R4DFCM199 Manual flush filter 1 1 F6RLCS204 Male union 2 1 R4DACC200 Filter cartridge 1 X X3AVSY119 Screw Chc M4 x12 steel 8 8 zinc plated 2 1 X2BDMU004 Washer M4 U zinc plated steel 2 1 Index revision F 46 11 FM approved Configurations HV generator molding Spray nozzle Cable length Option Guns 3 JR JP S28255 Bg gs x EN e 2 6 2 2 2 e o 2 JES E e 83 Model N Drawing a mm mm mm mm M M M M ie A Sa 2a Li Mach Jet Gun 1524463 X XX XX X X Xx S xX X Reference Mach Jet Gun Mach Jet Gun P N 6 M gt 1524463 12 M gt 1524463 12 References des Equipements de Pulv risation Spraying pattern P N equipment JR12 JR16 JR20 JR25 Buse Nozzle 1525493 1525493 1525493 1525493 Deflecteur Deflector 1411500 1409259 1409260 1411993 JP etroit JP medium JP large large JP Standard narrow medium standard Buse Nozzle 1525492 1525492 1525492 1525492
3. If this logo appears under V it indicates that the generator has shut down because of a fault A see 6 8 1 page 24 When the trigger is pressed this logo flashes the arrow indicates presence of high voltage atthe bottom of area 4 Index revision F 15 6336 5 3 Summary Selection of U and pre programmed characteristics from spray gun or control module is only possible if the operator is not painting Powder flow rate is adjustable high voltage activated or not e From the control module e From the spray gun It is possible to powder coat regardless of the menu in progress with the exception of the Cleaning menu The operator may return to the factory parameters at any time see 6 1 page 17 The operator may switch to a cleaning screen by pressing button 4 regardless of the screen displayed for more than two seconds Index revision F 16 6336 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 Pressing buttons 1 and 2 simultaneously until appearance of the logo at the top left hand side enables the device to restart with factory parameters The operator is thus in a first start up situation 6 2 Start up screen 6 2 1 Manual unit without PLC connection This screen enables selection of vibrating table or fluidisation tank When the vibrating table is used the auxiliary pneu
4. 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 and indication of Mach Jet version e F Unit configuration either vibrating table or fluidisation tank only in the case of using a Carriage e G Configuration with computer link only in the case of a manual unit connected to an industrial PLC e H Choice for the type of the characteristics U I 1 or U I 2 e Cleaning screen Standby screen 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 powder flow rate is set at 9 The cloud at the spray gun outlet is partially filled 9 12 and the pre programmed characteristic is that of the round spray nozzle 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 Without PLC The graphic icon V appears under the menu index This description corresponds to the type of powder supply two are possible e V Use of vibrating table parameter indicated by default factory setting e F Use of fluidisation tank This choice can be made at any time by going to the F menu
5. item 4 from the handle assembly item 5 Be careful not to pull out the three high voltage unit connection wires e Unscrew the three screws item 3 manually to disconnect the high voltage unit 7 4 2 Assembly e Connect the 3 power supply wires complying with the wiring diagram see illustration Check alignment of the three contacts Fully tighten manually without forcing e Fit the handle assembly to the gun Check the position of the wires to avoid possible pinching by the handle assembly Push until stop is reached e Refit the four screws and washers items 1 and 2 DES02714 DES02986 WARNING When unscrewing the screws it is possible that the washers may remain in place Loosen them using a 3 mm max screwdriver and remove them Change these washers each time the screws are removed e Tighten these screws to a torque of 0 5 NM Index revision F 32 6336 7 5 Trigger 7 5 1 Disassembly e Using a dia 1 5 mm drift punch remove the pin fixing the trigger to the handle assembly see figure 1 Be careful not to lose the spring 7 5 2 Assembly e Replace the spring around the magnet as shown in figure 2 e Place the trigger in its housing port upwards as shown in figure 3 e Replace the pin It must be correctly centred and must not protrude from either side Index revision F 33 Figure 1 Figure 3 DES02712 6336 7 6 Hand rest 7 6 1 Disassem
6. Con Item P N Description Qty of Emer ALO sale gency 1524463 Mach Jet Spray Gun 1 1 1524463 12 Mach Jet spray gun assembly with 4 4 _ _ 12 m cable 1 1524464 Gun assembly see 10 2 page 41 1 1 Fan spray nozzle assembly 7 ienan see 10 5 1 page 44 A Medium fan spray deflector 3 1313519 see 10 5 1 page 44 1 1 or 10 X 4 1311739 Nozzle nut 1 1 X Round spray nozzle assembly j SERES see 10 5 2 page 44 f L 6 1411993 Round spray deflector Dia 25 mm 1 1 7 X3GJCP004 Screw PT KA25x6 WN1412 galvanised o i steel cross head 8 1524468 Electronic board 1 1 9 J2FTCS435 O ring silicone 1 1 10 X3GJBP484 Screw PT KA30x20 WN1411 galvanised 7 i x steel cross head 11 J4BRNDO39 Fibre seal 7 1 X 10 1524465 Cable assembly length 6m 1 1 X 1526699 Cable assembly length 12m Option 1 X 13 U1FGBAO92 Powder hose 11 x 15 6 m X 14 1411501 Powder connector assembly 1 1 or 10 X 15 1525793 Vertical powder pipe assembly 4 4 x see 10 4 page 43 16 1525908 Handle assembly see 10 3 page 42 1 1 17 1313078 hand rest included in item 4 4 18 1313349 Large size hand rest Option 1 Index revision F 40 6336 10 2 Gun assembly Ref 1524464 o N N o 99 LL Q Unit First Con Item P N Description Qty of Emer ai sale gency 1 1524464 Gun assembly 1 1 F 2 J2CTCN115 O ring 1 1 X 3 1409
7. power supply Parts to be painted must have a resistance in relation to the ground system that is less than or equal to 1 MQ Index revision F 5 6336 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 by pressing the spray gun trigger 10 Only SAMES original spare parts guarantee operating safety of the equipment 11 Ambient temperature must not exceed 40 C 12 Switch off the electrical supply of the CRN 457 module before connecting the spray gun Before disconnecting the spray gun the atomizer extinguish switch off the power supply of the CRN 457 if not a malfunction 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 F 6 6336 2 Presentation The Mach Jet spray gun is a manual spray gun intended for powder spraying It is connected to a CRN 457 control module that controls both the high voltage and the powder flow rate of the spray gun to
8. which it is connected These two indissociable elements constitute a manual powder coating device This new spray gun integrates powder flow rate management and pre programmed voltage and current settings which are adjustable from the control module DES02501 DES02521 Index revision F 7 6336 3 Characteristics 3 1 General characteristics Mach Jet Spray Gun Temperature range for use 0 to 40 C Maximum output voltage 80 kV 5kV 9kV Maximum output current 110 WA or 10 LA Supply pressure 7 bar 1 bar Maximum powder flow rate 24 kg h 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 mo h Maximum air flow rate for auxiliary pneumatic output 12 mo h U KV Pre programmed value characteristics Elbow TO d ss A E A AA gt Index revision F Example of performance curve Envelope curve 10 30 70 110 A Characteristics of soray gun output voltage and current 8 6336 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 3 C 38 F Maximum particle size of solid pollutants Class 3 i e 5 um Maximu
9. 0V rms output 400mA rms P input 741 bar s n 2005 48 00445 IP20 Module serial number APPROVED Software Wrk 2 07 S37 Index revision F Module program version 12 6336 5 Description of spray gun and control module The function of the manual spray gun is to spray powder electrically charged by a high voltage unit built into the spray gun that delivers up to 80 kV and 110uA Only pressure on the trigger enables start up of the power supply and electrical charging of the powder 5 1 Functions available from spray gun DES02502 Area 1 The red LED under each icon corresponds to the selected voltage current characteristic in progress Selection of a different characteristic is only possible if the trigger is released Factory settings Y Round spray nozzle mode application icon i Z U 70kV and 70uA Xx Fan spray nozzle mode application icon E ll U 80kV and 30uA N Pa Over powder coating mode application icon Z fl U 65kV and I 10uA NI Metallic powder mode application icon A E E The three LEDs are lit for this choice lt M E AAE Simultaneous flashing of all LEDs indicates a communication fault with the control module see 6 8 1 page 24 Area 2 Powder flow rate can be adjusted here e It can be reduced by pressing the button e or increased by pressing the button There are thirteen powder flow rate setting levels one of whic
10. 919 Horizontal powder pipe 1 1 X 4 1526475 Elbow assembly 1 1 X 5 J2CTCN363 O ring included in item 4 1 1 Index revision F 41 6336 10 3 Handle assembly Ref 1525908 Trigger detail DES02711 Unit First Csnsu Item P N Description Qty of Emer able sale gency 1 1525908 Handle assembly 1 1 2 X2DGSP017 Pin 1 1 X 3 1408849 Trigger spring 1 1 F 4 1313078 Small size hand rest 1 1 Index revision F 42 6336 10 4 Vertical powder pipe assembly Ref 1525793 DES02709 LS ae m Consu Item P N Description Qty of Emer able sale gency 1 1525793 Vertical powder pipe assembly 1 1 X 2 J2FENV160 O ring FEP 1 1 X 3 J2FTDF125 O ring Viton 2 1 X Index revision F 43 6336 10 5 Nozzles 10 5 1 Fan spray nozzle DES02720 Unit First Consi 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 1or10 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 5 2 Round spray nozzle a Unit First Co
11. D flecteur Deflector 1311409 1313519 1311793 1315957 Index revision F 47 6336
12. Guarantee 9 111 ACOUIQUONS ii A aos 5 12 Oalely REQUIQIONS o 2hi02ddsbatedtsaeeeeetedecddute de 5 TO ACS becca Bele ances oad agent on en a ee a ees oe 6 2 Presentation 7 3 Characteristics 8 3 1 General characteristics cia hb ROSAS RE RDA aR 8 3 2 Compressed air quality 9 A OpP TAUON gt RSS ss jets fs es so ASE a Se eet 10 4 1 Back of CRN 457 control module 12 LA E IMOQUIe CONNECION Sis id iaa 12 4 1 2 Module identification plate 12 5 Description of spray gun and control module 13 5 1 Functions available from spray gun 13 5 2 Functions available from control module 15 OS OUMIMAY dose eo ER rod 16 6 Use of the different control module menus 17 6 1 CRN 457 initialisation screen 17 62 Olall UD SCICON uta ib a 17 6 2 1 Manual unit without PLC connection 17 6 2 2 Manual unit with PLC connection o ooooooooooo 17 6 3 Cleaning screen only with a carriage 18 6 4 Standby screen only with a communication with a PLC 18 6 0 WAIN Seen A aia a or t l PS dis 19 MN A ee a Ce Dot to hee 21 OZ CEON CR a be eee 22 A A Baad uses dad ee O aes 23 06 QUE HSE ce pus RE dg AO Si dh J
13. Less menu or positioning on the Ph powder cleaning screen by pressing Es seconds S More f CA powder There are 13 different flow rates from 0 to 12 the U I characteristic remains unchanged and 0 corresponds to a zero flow rate the operator has access to the next menu B 2 This button enables selection of a pre set character istic U I Pressing this button gives a looped display of the following logos ea Use of a round spray nozzle Use of a fan spray nozzle ua Over powder coating applica tion Metallic powder application Index revision F 19 6336 The selected flow and U I characteristic are memorized after e 1 seconds without modification of flow parameters or U I characteristics e Change of screen e Trigger pressed Recommended settings 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 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 Use of a current in excess of 30 yA may result in reduced transfer efficiency and electrode soiling Application in over powder cove
14. ack Beare rasta eG 24 COOL D a npc ek 26 OO OO a ia ad oder 27 NES SA Bnd Boe aie a ndlr dde 28 OO CIO da Dita ibas Ges Bema eae arate io 29 ls NIGINTCH ANC Cio ense po ee o ere 30 Fil D TI CIOr an NOZZIC LL test te Beil Se age Meeks adi 30 LANAS ASS NV ada a APs ca das ion 30 AN AA to a oy RR th duree ia es 30 7 2 Vertical powder pipe 1 eee 30 Fhe DIS ASS CMD A ier Sok de dE MES sn Bad bth ls da ae Bg Od OAM 30 Pz TS CIE 0 STE BO wae BeOS ok ae ey Ce Be oa ads 30 Index revision 3 7 3 Powder elbow and horizontal pipe 31 Id Sas SON a ad RG la A a a 31 722 AS SOMO AR EA AS AS IEA 31 7 4 Handle assembly 32 LAMA IS ASS CMD wit acne DA A AA aaa 32 FAZ NS CON AI A A Roue 32 Vic opm MUDO ae ee nee eee ee ee aaa eee ea eee ene ee NO 33 F0 1 E AAA Agila RIT wh ca he toh he us 33 ESA PUSS CTI ION i Se her Sh sneak eis dat att dah meal ee che el Bea hal sl on a a 33 720 TIANO NOSE IR E e oh od ieee ea Bane ed 34 7 0 1 DIS ASS CMD id da tee he iy Meh BA ho dd dc 34 7 6 2 ReassemMOl AAA 34 PR UMN a ada crias EEE EEE TEE EET TE EE EEEE E EE 35 LAVAS AS SONO Void aa de de a de ask BS 35 file PASS 1410 AAA 35 7 0 GADIC ASSOIMOLV 2 six rd rta a GRE a oes 36 O DIS ES SCD Vd iS AAA ud MRS ee Se 36 PBA A A eee es ee ea al ae Go ae 36 8 Cleaning Maintenance 37 9 TTOUDIESNOOING esse ess esse A ess 38 10 Spare
15. ain relief on the stuffing box before proceeding with this operation Tighten the strain relief on the stuffing box Stage 9 Change the gun seal Stage 10 Reconnect the gun power supply wires see 7 4 2 page 32 Stage 11 Reposition the gun and handle assembly making sure not to pinch the gun power supply wires Stage 12 Install the vertical powder pipe see 7 2 2 page 30 Index revision F 36 6336 8 Cleaning Maintenance WARNING All cleaning operations must be done only with depressurized compressed air with a 2 5 bar maximum pressure a cloth or a brush if necessary Never use water or solvents to clean equipment with the exception of the deflector Fouling and wear of the 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 Switch off the CRN 457 mains power supply disas semble and clean the nozzle and compressed air elec trode Make sure that there is no accumulation of powder on the electrode Clean the powder ducts by blowing compressed air
16. bly e Place a flat screwdriver in the notch on the hand rest located on the handle assembly e Lever upwards slightly and remove the hand rest from its location Notch DES02701 7 6 2 Reassembly e Place the hand rest on the positioning pin and apply light pressure on the clipper a click must be heard Index revision F 34 Positioning DES02700 pin 6336 7 7 Gun 7 7 1 Disassembly e Follow handle assembly disassembly procedure see 7 4 1 page 32 e Remove the powder elbow and the powder pipe from the gun see 7 3 1 page 31 7 7 2 Assembly e Clean the gun replace it if necessary Change the gun seal making sure to position it correctly in the gun groove e Proceed in reverse order for reassembly see 7 3 2 page 31 then see 7 4 2 page 32 WARNING To guarantee correct sealing each time the gun is disassembled always replace the O ring Index revision F 39 6336 7 8 Cable assembly WARNING This operation is delicate and must be carried out with extreme care 7 8 1 Disassembly 7 8 2 Assembly Stage 1 Remove the powder pipe see 7 2 1 page 30 Stage 2 Unscrew the 4 screws fixing the handle assembly to the gun Stage 3 Unscrew the 3 electrical connection wires on the gun and remove it see 8 7 4 1 page 32 Stage 4 Unscrew the strain relief item 2 Unscrew the stuffing box item 1 using a 19 mm flat wrench unscrew the 3 screws item 3 from the base
17. e button validates the parameters the U l characteristic remains unchanged and the operator has access to the next menu C It is possible to powder coat and see the influence of adjustments before validating If no action is taken the display switches auto matically to screen A after one minute Index revision F 2 This button enables selection of the pre set characteristic U l Pressing this button gives a looped display of the following logos i yA Use of round spray nozzles Use of fan spray nozzles Ed Over powder coating applica tion Metallic powder application 21 6336 6 7 Screen C It is used to modify the voltage and current settings of the characteristic selected in menus A and B DESo2495 1 Voltage or current can be modified in 3 This button enables this area switching to the following menu or positioning on the The voltage or current value cleaning screen by pressing decreases when the flashing the button for more than two E cursor is opposite the parame seconds hea ter to be modified A The voltage or current value increases when the cursor is opposite the parameter to be Pressing the button validates the parameters modified and the operator has access to the next menu D When values are modified the hand logo If no action is taken the display switches appears see 2 automaticall
18. er e Gently withdraw the gun assembly item 5 y from the handle assembly item 6 Be careful not to pull out the three contact screws high voltage unit connection item 3 e Remove the powder elbow item 4 by pulling it towards the handle assembly e Horizontal powder pipe removal Operation necessary only when replacing the powder pipe insert the new pipe into the gun nozzle nut side and push out the old one 7 3 2 Assembly e Clean the interior of the powder pipe located in the gun with compressed air DES02713 e Check the state of the elbow and its seal Clean with compressed air and replace if necessary e Insert the elbow with its seal into the horizontal powder pipe the elbow seal must no longer be visible from the outside e Fit the four screws and washers WARNING When unscrewing the screws it is possible that the washers may remain in place To extract them use a maxi 3mm screwdriver and remove them bu pushingfrom the interior of the handle Change these washers each time the screws are removed e Use a torque screwdriver to tighten these screws to a torque of 0 55 NM Index revision F 31 6336 7 4 Handle assembly 7 4 1 Disassembly e Follow vertical powder pipe disassembly procedure see 7 2 1 page 30 e Unscrew the four screws item 1 located on the back of the spray gun using a Philips PH 1 tip screwdriver and remove the washers item 2 e Gently withdraw the gun assembly
19. h is zero The operator can display the powder flow rate on the CRN 457 control module A powder cloud fills up with an index varying from 0 to 12 there is no corresponding display on the spray gun On start up of the spray gun the powder flow rate value is O zero flow rate It is possible to select the flow rate without having to press the trigger Index revision F 13 6336 Area 3 This area is used for selecting pre programmed voltage current characteristics On start up a red LED lights up below the round spray nozzle icon and pressing the U I button ena bles selection of one of the four characteristics WARNING For guns sold in 2006 it will be then possible to display the cleaning screen by pressing onto U l key for 2 seconds The output of this screen is similar to the input one If E screen mentions Mach Jet V gt or 1 this function is available if E screen mentions Mach Jet V 0 the gun is not equipped with this function Index revision F 14 6336 5 2 Functions available from control module The control module displays use parameters and their settings which can be changed using the four buttons on the front panel CRN 457 control module front panel The operator has access to menus from A to H and to a cleaning screen e A Powder flow rate adjustment and selection of pre set characteristics U I e B Dilution air adjustment and selection of pre set characteristics U l
20. ly pull it It is not necessary to remove the nozzle nut Nozzle e Remove the deflector e Unscrew the nozzle nut manually e Remove the nozzle 7 1 2 Assembly e Proceed in reverse order having first checked and cleaned the different components Replace them if necessary 7 2 Vertical powder pipe 7 2 1 Disassembly e Remove the powder union e Start unscrewing the powder pipe using a 17 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 handle assembly 7 2 2 Assembly e Clean the interior of the powder pipe with compressed air e Check the state of the seals and the powder pipe Replace them if necessary e Install the pipe in the handle assembly it locates automatically in the powder elbow then push it in until it stops e Tighten manually then continue tightening using the 17 mm ring wrench e Connect the powder union to the vertical pipe Index revision F 30 6336 7 3 Powder elbow and horizontal pipe The powder elbow guarantees the connection between the horizontal powder pipe located in the gun and the vertical powder pipe located in the handle assembly 7 3 1 Disassembly With the powder pipe already removed see 7 2 1 page 30 e Remove the four screws and washers 1 2 located on the back of the spray gun items 1 AA A and 2 using a Philips PH 1 tip screwdriv
21. m oil concentration Class 1 i e 0 01 mg m Maximum concentration of solid pollutants Class 3 i e 5 mg m a 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 5ufilter 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 10 6 page 46 If any damage on the equipment happens because of a polluted air the warranty could be not applied Index revision F 9 6336 4 Operation The Mach Jet spray gun is connected to the CRN 457 control module via a serial link embedded in the electrical connection cable This link enables recognition of the spray gun and the exchange of data necessary for operation Methods for modifying or adjusting settings are described in the following chapters It is possible to return to the original factory settings at any time see 6 1 page 17 In the case of a manual unit not connected to an industrial PLC The first time the control module is started up the operator selects the operating mode for powder feed two possibilities are proposed e Use of a vibrating table factory parameter e Use of a round fluidisatio
22. matic outlet is activated while the trigger is pressed When the fluidisation tank is used activation occurs 30 minutes after the last pressure on the trigger 6 2 2 Manual unit with PLC connection Index revision F 17 6336 6 3 Cleaning screen only with a carriage 1 This button starts up or stops the cleaning mode Pressing the 0 1 button puts the system in cleaning mode a computer animation appears on the screen flashing Cleaning mode must be stopped before pro ceeding with the next operation The spray gun commands are disabled 2 This button enables switching to the following menu Pressing the button is forbid den when the installation is in cleaning mode 6 4 Standby screen only with a communication with a PLC Index revision F 1 Pressing this button quits Standby mode Pressing this button quits Standby mode and triggers an automatic return to screen A Spray gun commands are disabled in this screen 18 6336 6 5 Main screen A This screen enables selection of work parameters and display of spray gun operation From the keyboard the operator can select the powder flow rate and a pre set characteristic U I DESO2511 this area switching to the following the button for more than two Pressing the button validates the parameters 1 Powder flow rate can be adjusted in 3 This button enables
23. n tank WARNING This use parameter can then be modified at any time in the F menu displayed on the control module Index revision F 10 6336 In the case of a manual unit connected to an industrial PLC In this case the spray gun is connected to the PLC via the PLC plug The following parameters must be entered on start up Parameters Factory value Minimum Maximum Remote mode Slave index 1 1 99 Remote mode Communication speed 9 600 baud 1 200 baud 38 400 baud Auxiliary EV action synchronised with the 0 0 4 trigger 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 Front of CRN 457 module manual unit with PLC connection Index revision F 11 6336 4 1 Back of CRN 457 control module 4 1 1 Module connections Pneumatic output General power supply Injection mu B Y J h e ha a 4 Y 1 Sa 4 ei CC cm zi A el wit CA UT Pi ik a _ jpe i asr yr fin 1 2st Pneumatic or Dilution 4 1 2 Module identification plate To Sames Base da B PLC plug Pneumatic output auxiliary rat table tank Start stop switch 7 0 o Base plate A Ground Spray gun plug terminal e CRN457 1523297 _ Meyen France EN 50050 0080 Ex 1 2 D ISSeP04ATEX119 EEx2mJ 190 270V 50 60Hz GOVA U output 4
24. nu A Immediate return to screen A if the trigger is pressed Index revision F 28 6336 6 12 Screen H It is used to select the type of characteristics U l or U l U l type is the most common one The electrostatic power is the highest one It allows painting a part even at a far distance U l type allows reducing the electrostatic power when the operator moves away from the part This type of characteristics avoids the hand of the operator to be covered with paint WARNING With U I2 the part has to be painted at a maximum distance of 300 mm otherwise the electrostatic effect is weakened 1 This button allows selecting U l or 2 This button enables U l characteristics switching to the following menu or positioning on the cleaning screen by pressing Pressing this button moves a flashing pointer the button for more than two on in front of the using mode seconds the operator has access to the next menu A Immediate return to screen A if the trigger is pressed Index revision F 29 6336 7 Maintenance WARNING Switch off the electrical supply of the CRN 457 module before connecting the spray gun Before disconnecting the spray gun the atomizer extinguish switch off the power supply of the CRN 457 if not a malfunction can occur 7 1 Deflector and nozzle 7 1 1 Disassembly Deflector e To disassemble the deflector simp
25. pants IS gt 2 053 SES mess ia Sees 39 10 1 Mach Jet Spray Gun Ref 1524463 39 10 2 Gun assembly Ref 1524464 41 10 3 Handle assembly Ref 1525908 42 10 4 Vertical powder pipe assembly Ref 1525793 43 TO INOZZCS rata ia at ias ie 44 10 5 1 Fan spray NOZZ O cir ds ent he A AAA A we 44 10 5 2 Round spray nozzle 44 10 5 3 Extended nozzle length 150 mm 45 10 5 4 Extended nozzle length 250 mm 45 10 6 EQUIDAD oS EPS ARS 46 11 FM approved Configurations 47 Index revision 4 1 Regulations Safety Regulations and Guarantee 1 1 Regulations The Mach Jet spray gun is in conformity with standard EN50050 2001 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 S Somes DS 4 Meylan France EN 50050 CE 0080 12 D MACH JET GUN 4 0080 EX 1 2 D a ISSePO4ATEX119 When configured EEx2mJ 1P20 lt A gt according to 800000045 90 270V 50 60Hz GOVA APPROVED U output 40V rms output 400mA rms P input 741 bar lt gt wd ue AAN ITA DES02727 1 2 Safety Regulations This equipment may be dangerous if it is not used in compliance with the security
26. plate item 4 to separate it from the handle assembly and lower the base plate to unscrew the green yellow wire fixing screw item 5 Stage 5 Remove the box Hall effect sensor Item 8 figure 2 from its housing located behind the trigger in the upper part of the handle assembly using a flat screwdriver Stage 6 Unscrew the end of handle assembly board item 6 figure 2 and remove it from the handle assembly Stage 7 Unplug the black connector item 9 figure 2 Stage 8 Unscrew the strain relief item 7 figure 2 located on the shield of the electronic board Stage 9 Remove the cable from the handle assembly DESO2715 DES02726 Stage 1 Take a new cable equipped with its base plate Stage 2 Insert the cable into the handle assembly ensuring that it is correctly positioned see figure 2 Be careful not to pass the cable through the powder pipe housing Stage 3 Fix the strain relief item 6 figure 2 recovered to the shield of the board ensuring that it is correctly positioned Stage 4 Connect the connector to the board Stage 5 Fix the board item 5 figure 2 in the bottom of the handle assembly using the two screws Stage 6 Replace the sensor box item 7 figure 2 in its housing Stage 7 Fix the green yellow wire item 4 figure 1 to the handle assembly base plate Stage 8 Reassemble the base plate item 3 figure 1 retighten the stuffing box to a torque of 3 5 NM it is necessary to loosen the str
27. 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 1 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 gloves 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 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 Skin contact with or inhalation of products used with this equipment may be dangerous for personnel cf Safety sheets for products used 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
28. ressed 2 This button display in a loop ground ground reverses the screen colour Pressing this button reverses the Either the graphics are orange on a black back Or the graphics are black on an orange back Index revision F 6336 6 10 Screen F This screen is used to select the powder supply vibrating table or fluidisation tank therefore only in the case of a manual unit with no connection to a PLC 1 This button enables selection of the powder supply mode Pressing this button moves the flashing cur sor in front of the operating mode Index revision F 27 2 This button enables switching to the following menu or positioning on the cleaning screen by pressing the button for more than two fo seconds O Pressing the button validates the parameters and the operator has access to the next menu A If no action is taken the display switches automatically to screen A after one minute Immediate return to screen A if the trigger is pressed 6336 6 11 Screen G This screen is used to consult the adjustment parameters for remote mode only in the case of a manual unit connected to a PLC 1 This button enables switching to the following menu or positioning on the cleaning screen by pressing the button for more than two pa seconds ae The operator has access to the next me
29. ring 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 lt 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 To optimize the aspect of the part tight crater the operator may have to increase the voltage up to 50kV and to decrease the current down to 5uA Index revision F 20 6336 6 6 Screen B It is used for dilution air adjustment and selection of pre set characteristics U I Dilution air is used to avoid spray pulses This adjustment also acts on powder spray speed ES Y 1 IL 1 Dilution air can be adjusted in this area Less air r o Slower spray Pu Risk of a ii pulses More air a _ Faster spray i 2 Fewer ae g pulses There are 7 different settings from 3 to 3 3 This button enables switching to the following menu or positioning on the cleaning screen by pressing the button for more than two fo seconds RE Pressing th
30. screen as long as the temperature is too high The operator will have to make the temperature decrease Make sure as well that the temperature of the compressed air is lower to 40 C Le 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 gun The spray gun is rearmed by releasing the trigger and pressing it again If the fault reappears systematically check the wiring of the gun 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 F 25 6336 6 9 Screen E This is used to adjust the screen 1 Screen contrast can be modified in this area Pressing the buttons corresponds to Reducing contrast the screen becomes increasingly brighter Increasing contrast the screen becomes increasingly darker 3 This button enables switching to the following menu or positioning on the cleaning screen by pressing the button for more than two pa seconds po Pressing the button validates the parameters and the operator has access to the next menu F or Q with a PLC If no action is taken the display switches automatically to screen A after one minute Immediate return to screen A if the trigger is p
31. through the powder end piece below the handle assembly without disassembling it Between 40 and 60 hours of work Clean the round spray deflector by leaving it to soak for a few hours in methyl isobutyl ketone MIBK From 3 to 6 months Check the state of wear and soiling of the powder elbow replace it if necessary WARNING MIBK solvent is toxic and flammable Index revision F 37 6336 9 Troubleshooting Symptoms Probable causes Remedies Drop in powder flow rate Elbow soiling Disassemble the spray gun clean it or replace the elbow Clogging of powder supply hose Unclog the powder hose using com pressed air Wear and fouling of powder pump Refer to powder pump user manual Powder does not adhere to the part No high voltage Incorrect connection of daisy chain following assembly disassembly Low voltage cable cut off Check the three high voltage unit con nections Replace the low voltage cable Incorrect U l adjustment Use factory settings Incorrect pneumatic adjustment Use factory settings Index revision F 38 6336 10 Spare parts list 10 1 Mach Jet Spray Gun Ref 1524463 10 E Sames Z 11 10 X 18 5 9 17 16 10 11 15 DES02722 Index revision F 39 6336 Unit First
32. tification of the fault and its number The operator confirms its recognition by validating with button 4 Index revision F 23 6336 6 8 1 Fault list Fault number Icon Comment E 1 al CRN 457 general fault 2 TT No Mach Jet connection 3 E a CRN 457 temperature excessive Som A 4 ig High voltage action forbidden oe e 5 a CRN 457 general fault 1 6 TES CRN 457 general fault E 7 ST CRN 457 general fault w 8 LR CRN 457 general fault E 9 S Short circuit 10to 18 Solenoid valve index Vi V1 to V8 KES 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 2 is a communication problem caused by a damaged or disconnected cable no link with the Mach Jet spray gun Index revision F 24 6336 Fault 3 is caused by excessive temperature inside the control module In case of the control module should reach a too high temperature risking damaging it the high voltage is switched off and a warning message is displayed on the control module Work can be continued by pressing once on to the trigger to acknowledge the fault but this latter will come back every minute as long as the temperature has decreased to an acceptable level An alarm will remain displayed on the
33. u Item P N Description Qty of Emer mable sale gency 1 1525493 Round spray nozzle assembly without deflector 1 1 X 2 1412250 Conductor O ring included in item 1 1 1 X 3 J2CTPCO20 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 1 or 10 X 1411993 Round spray deflector Dia 25 mm white Option 1 X Index revision F 44 6336 10 5 3 Extended nozzle length 150 mm DES02981 Unit First Gansu Item P N Description Qty of Emer able sale gency 1 1526297 Extended nozzle length 150 mm 1 1 2 1412250 Conductor O ring included in item 1 1 1 X 3 x NvcB187 gt O M 5 x 25 nylon 1 1 included in item 1 10 5 4 Extended nozzle length 250 mm 2 3 a Unit First Consi Item P N Description Qty of Emer able sale gency 1 1526298 Extended nozzle length 250 mm 1 1 2 1412250 Conductor O ring included in item 1 1 1 X a Oe Mea Ces Ion included in item 1 45 6336 Index revision F 10 6 Equipment o Unit First Caneu P N Description Qty of Emer hable sale gency 1523297 CRN 457 control module 1 1 E4PCAL206 Europe Main power cable 1 1
34. y to screen A after one minute The hand logo disappears on return to factory parameters 2 This button pinpoints the parameter U or I to be modi fied aa If U is to be increased decreases po automatically if positioned on the envelope curve St of the characteristic see 3 1 page 8 and vice versa ESO2512 Index revision F 22 6336 6 8 Screen D This screen is used to display the history of faults encountered DESC2406 11 The history of the most recent faults 2 This button enables can be displayed in this area The last fault switching to the following with its index 4 in this case appears on menu or positioning on the the screen The fault s age index is indi cleaning screen by pressing cated on the left hand side of the screen the button for more than two n s 0 seconds a Display of faults from oldest to If no action is taken the display most recent switches automatically to screen A after one minute Immediate return to screen A if the trigger is e Display of faults from most pressed recent to oldest 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 iden
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