Kremlin-Rexson PU 3000, Instruction Manual

Page 1: ...re assembly and start up please read and clearly understand all the documents relating to this equipment professional use only THE PICTURES AND DRAWINGS ARE NON CONTRACTUAL WE RESERVE THE RIGHT TO MAKE CHANGES WITHOUT PRIOR NOTICE KREMLIN REXSON 150 avenue de Stalingrad 93 245 STAINS CEDEX France Téléphone 33 0 1 49 40 25 25 Fax 33 0 1 48 26 07 16 www kremlin rexson com ...

Page 2: ...X AND OF THE FLUID FRAME 13 6 OPERATING 13 DRIVING FROM THE MACHINE 13 SWITCHING ON THE MACHINE 13 7 FIRST SWITCHING ON 15 8 FIRST PLACING INTO OPERATION 16 BEFORE SWITCHING ON 16 FLUSHING OF THE PUMPS AND OF THE MACHINE IN SOLVENT 16 START UP OF THE MACHINE 17 MIXING RATIO CHECKING 17 9 APPLICATION PROGRAMMING F3 18 PASSWORD 18 PARAMETERS 19 VALIDATION OF THE INITIALIZATION MODE 20 PRODUCTION F1 ...

Page 3: ...0 AIRMIX 32 COMPOSITION 32 TECHNICAL FEATURES 32 SPECIFIC PARAMETERS 32 17 DISASSEMBLY REASSEMBLY PU 3000 PNEUMATIC PU 3000 AIRMIX 33 MIXER 33 PILOTED VALVES 33 FLUID SECTION MODEL 50 BASE REFER TO DOC 573 080 050 34 FLUID SECTION MODEL 50 F CATALYST REFER TO DOC 573 114 050 36 18 FEATURES PU 3000 AIRLESS 39 COMPOSITION 39 TECHNICAL FEATURES 39 SPECIFIC PARAMETERS 39 19 DISASSEMBLY REASSEMBLY PU 3...

Page 4: ... 573 415 050 HP fluid regulator model 3 8 260 bar 3771 psi Doc 573 299 050 PU 3000 AIRMIX PU 3000 Airmix Pump Assembly Doc 573 386 050 Pneumatic motor model 3000 Doc 573 387 050 BASE fluid section model 50 Doc 573 080 050 CATA fluid section model 50F Doc 573 114 050 Color changer and valve Doc 573 187 050 Doc 573 188 050 Filter model HP 3 8 260 bar 3770 8 psi Doc 573 299 050 PU 3000 AIRLESS PU 300...

Page 5: ...injury This equipment is for professional use only It must be used only for what it has been designed for Never modify the equipment The parts and accessories supplied must be regularly inspected Defective or worn parts must be replaced Never exceed the equipment components maximum working pressure Comply with regulations concerning safety fire risks electrical regulations in force in the country ...

Page 6: ...plate with the name of the manufacturer the equipment part number the interesting informations to use correctly the equipment pressure voltage and the above pictogram The equipment is designed with and consists of high quality materials and components which can be re used The 2002 96 EC European Directive covers all equipments with a crossed out bin pictogram Please inform yourself about the colle...

Page 7: ... 5076 psi It is under an independant form only supplied with compressed air maximum 6 bar 87 psi and an electric supply 115V 230V It consists of a control box with PLC and electromagnetic control components a frame supporting a BASE pump a CATALYST pump the automatic valves for the materials and the solvent and electropneumatic control components A Electronic control box with display unit B Air eq...

Page 8: ...e operating of the machine real time display of the ratio of the consumption can be read on the LCD screen The PU 3000 continously saves data on the consumptions of base catalyst and solvent as well as the total consumptions and the emissions of Volatile Organic Compounds VOC during the operation of the machine On the box of the machine a seal gland enables an electrical supply to the machine with...

Page 9: ...r Automatic flushing cycle time VOC display Consumptions total indicator base cata solvent VOC Printing connection to a printer Voltage 230V 115V 10W Air pressure Mini 4 bar 58 psi Maxi 6 bar 87 psi Operating pressure from 0 6 bar 0 87 psi or from 6 40 bar 87 580 psi for the pneumatic version from 30 to 180 bar from 436 to 2610 psi for the Airmix version from 60 to 350 bar from 870 to 5076 psi for...

Page 10: ...the pump and shall not be used for the handling of the complete machine The frame has 4 holes 9 to be fixed on a bracket or on the floor STORAGE Storage before installation Storage ambient temperature 0 50 C 32 122 F Protect the equipment against dust running water dampness and shocks Storage after installation Operating temperature 15 35 C 52 95 F Protect the equipment against dust running water ...

Page 11: ...ive Marking according to the ATEX Directive KREMLIN REXSON STAINS FRANCE Name and address of the manufacturer CE II 2 G II group II 2 class 2 Surface equipment meant to area where explosive atmospheres due to gas vapours mists are liable to appear from time to time in usual operating G gas P air 6 bar 87 psi Maximum air pressure P prod Maximum fluid pressure Série Serial Number given by KREMLIN RE...

Page 12: ...ump option 11 Gun not supplied 5 HP fluid hose 12 Gun spraying air from the machine The 1 m 39 37 distance indicated in these diagrams is given for information only and holds harmless KREMLIN REXSON The user is liable for the exact delimitation of the areas which depends on the material used the material environment and on the use conditions refer to EN 60079 10 standard The 1 m 39 37 distance cou...

Page 13: ...that are not intrinsically safe INSTALLATION There are different ways to install the PU 3000 to answer to the majority of the installations The control box of the PU 3000 mixing machine must be installed outside the spray booth in a safe area Assembly for piloting outside the booth The machine is in two parts to enable the control box to be fitted outside the booth cable of 8 m 26 2 ft between the...

Page 14: ...ted on the frame is carried out via cable length 8 m 26 2 6 OPERATING DRIVING FROM THE MACHINE SCREEN Different menus and information relating to the machine are displayed on the alphanumeric screen KEYBOARD ESC That key enables the user to quit the menus or the different modes production flushing parameters OK That key enables the user to enter in the different menus or to validate a value of par...

Page 15: ...um 4 bar 58 psi Switch on the control box switch located on the side of the box When switching on the control box a menu is displayed on the screen Nota Parameters have been set up in the factory before the delivery of the machine You must adapt the parameters to the use They must be modified by an authorized person refer to list of parameters ...

Page 16: ...ion F2 flushing F3 parameters F4 consumptions F5 normal operating of the pumps To surf from a menu to another you must move placing the magnet on the sensors indicated with The menus scroll as follows Arborescence of the menus Production Flushing Parameters Consumptions Pumps Countdown on fluid life time countdown from 9 to 0 9 represents 90 of the remaining time before the regeneration A line is ...

Page 17: ...t the A pump or and OK Trigger the gun to start the A pump with solvent and increase the fluid pressure to at least 1 bar 14 5 psi reading on the gauge or go through the drain valves Release the gun trigger when there are no more air bubbles in the solvent at the gun nozzle Immerse the suction rod of the CATALYST pump in a solvent container On the page of the display main menu enter NORMAL OPERATI...

Page 18: ...adjust the opening of the needle valve Prime the B pump and adjust the opening of the needle valve Place the beakers underneath the valves Start up the PU 3000 pump then open the valves Input The PU 3000 passes in test mode and displays Caution the fluid pressure must be lower than 200 bar 2900 6 psi The BASE and CATA materials are dispensed into the beakers After a while close the needles valves ...

Page 19: ...f the menu Parameters is deactivated everyone is able to modify the machine s parameters To activate this access code you have to enter in the parameter 0 of the menu F3 key key The code appears it s the code present by default in the machine change the code by using the arrows or and the key for each digit which compose this code Once the access code was validated the access is protected by the p...

Page 20: ...Minimum value 1 mm2 Maximum value 99 999 mm2 For fluid section 50F 470 airmix version 490 pneumatic version For fluid section 124cc 555 airless version Injection volume Minimum value 0 1 cc Maximum value 999 9 cc 4 8 cc Mixing tolerance Minimum value 0 1 Maximum value 100 3 Alarm volume for the A pump Minimum value 1 L Maximum value 40 000 L 0 parameter not taken into account OK reset of low level...

Page 21: ...OK Then the piston displays A2 it goes up and is waiting for the high setting of the BASE pump Open the gun or the BASE drain valve to make the piston go up Input OK The machine displays b1 and controls the down stroke of the CATA pump piston open the gun or the CATA drain valve to make the piston go down Once the CATA pump piston is in low point close immediately the valve or the gun avoid the de...

Page 22: ...io is displayed on the screen The machine stops because of a malfunction The kind of breakdown is displayed on the screen the machine emits an alarm signal to inform the operator cf TROUBLESHOOTINGS The machine has reached the maximum life duration of the material and passes automatically in regeneration mode The machine emits an alarm signal to inform the operator The following screen is displaye...

Page 23: ...first flushing you can determine the solvent volume F3 P12 parameter consumed during the flushing time F3 P11 parameter Once determined enter your parameters accordingly CONSUMPTIONS PRINT F4 The F 4 menu enables to view the consumptions of each material color catalyst in cc You can also print the ratio of the consumptions as well as the parameters of the applications you must connect a connection...

Page 24: ...reset the consumption of solvent activating the key OK Preventative maintenance display if the number of preset cycles on P14 15 is reached it enables the user to reset the counters of cycle of the A and B pumps for the preventive maintenance Only when the counter has been reached its value activating the key it reinitializes the counter Enables the user to reset all the consumptions activating th...

Page 25: ...y but do not stop the machine Number of cycles overrun indication Messages Indications Cyc A Overrun of the number of cycles configured at the P3 parameter Cyc b Overrun of the number of cycles configured at the P14 parameter Cyc Ab Overrun of the number of cycles configured at the P13 P14 parameters Fluids consumption alarm Messages Indications A A fluid consumption alarm A container empty volume...

Page 26: ...perly adjust the potlife parameter to avoid curing Carry out a flushing when the work is over Flush when ending the work SYNOPTIC A B AC 230 115 V AC EV D1 D1 D2 A SA B info moteur B info moteur A câble long 8m MEL 50 50F 10 14 VP1 VP2A VP2B A B SA A B SA D2 S VR1 Nota diagram of a pump model PU 3000 Airmix ...

Page 27: ...ur colourless 2 mn week stop P lubricant If the lubricant is contaminated tighten the wetting cup on the upper packing or change the seals of the packing if necessary 10 mn month stop Wrench supplied CATA fluid section model standard Remove and clean the parts change the seals and reinstall 3 h 1 year stop CATALYST pump CATA fluid section model Flowmax Remove and clean the parts change the seals a...

Page 28: ...ad contact or other TROUBLES CAUSES SOLUTIONS Trouble on the BASE fluid section Check the BASE circuit material in the drum suction rod strainer pump valves Clean or change Check the CATALYST pressure towards the BASE pressure Trouble on the CATALYST fluid section Check the CATALYST circuit material in the drum suction rod strainer pump valves Clean or change Check the CATALYST pressure towards th...

Page 29: ... grounds of the machine 230V intake and ground cable of the fluid module The machine displays the correct mixing but the consumption of catalyst is not enough Check the grounds of the machine When the main menu page is displayed fluid flows out when the gun is open Check the valves Checking of the valve look at what is flowing if it is solvent change the valve VP1 if it is base change the valve VP...

Page 30: ...33 2 5 1 40 12 5 1 8 3 1 33 3 13 1 7 692 3 5 1 28 6 13 5 1 7 407 4 1 25 14 1 7 143 4 5 1 22 2 14 5 1 6 897 5 1 20 15 1 6 667 5 5 1 18 2 15 5 1 6 452 6 1 16 7 16 1 6 25 6 5 1 15 4 16 5 1 6 061 7 1 14 3 17 1 5 882 7 5 1 13 3 17 5 1 5 714 8 1 12 5 18 1 5 556 8 5 1 11 8 18 5 1 5 405 9 1 11 1 19 1 5 263 9 5 1 10 5 19 5 1 5 128 10 1 10 20 1 5 14 PNEUMATIC AND ELECTRIC DIAGRAMS Refer to appendices Doc 05...

Page 31: ...KREMLIN REXSON Page 30 Manual 573 199 112 SPECIFICATIONS PU 3000 PUMP model Pneumatic model Airmix ...

Page 32: ... psi or 6 40 bar 87 580 psi Proportioning ratio Fluid flow rate Refer to charts 14 15 Electrical supply of the supply unit 115V 230V 10W Air inlet connection F 3 4 BSP air inlet valve Fluid outlet connection mixer F 3 4 JIC The control box of the PU 3000 mixing machine must be installed outside the spray booth SPECIFIC PARAMETERS Parameters Description Factory adjustment Your adjustments Section o...

Page 33: ...i Proportioning ratio Fluid flow rate Refer to charts 14 15 Electrical supply of the supply unit 115V 230V 10W Air inlet connection F 3 4 BSP air inlet valve Fluid outlet connection mixer F 3 4 JIC The control box of the PU 3000 mixing machine must be installed outside the spray booth SPECIFIC PARAMETERS Parameters Description Factory adjustment Your adjustments Section of the A piston Minimum val...

Page 34: ...old the rod strainer 6 unscrew the needle rod and remove the cartridge assembly with rod 9 Assemble the new cartridge 9 into the cylinder support 2 pushing it until the shoulder of the cartridge rests on the shoulder of that support then reassemble all parts of the valve in the reverse order of the disassembly Present the valve in front of the module body Center the cartridge 9 on the module body ...

Page 35: ...e GT seal 13 the GT washer 12 and the ball 17 on the exhaust valve 6 Screw the exhaust valve 6 into the piston Tighten up the seal on the exhaust valve 6 Change the seal 8 if necessary when assembling the cylinder 2 UPPER PACKING Disassemble the piston rod from the motor and the piston 3 from the fluid section Unscrew the wetting cup 4 by means of the wrench supplied with the pump Pull the piston ...

Page 36: ... 12 13 6 8 2 25 9 10 26 5 24 23 1 3 A 2 A 1 A 1 A 2 A 2 A 1 A 1 A 2 A 1 C 1 A 1 A 1 Index Instruction Description Part number A 1 PTFE grease TECHNILUB grease 10 ml 560 440 101 A 2 WEICON AS1000 grease WEICON AS1000 grease box 1 kg 2 204 lb 560 420 005 C 1 Medium strength Aneorobic Pipe sealant Loctite 577 ...

Page 37: ... Change the tightness seal 28 the O Rings 29 and 11 Reinstall the parts in the reverse order of the disassembly sequence 2 DISASSEMBLY ASSEMBLY OF THE COUPLING WITH BELLOWS That operation must be carried out after the disassembly of the fluid section part BELLOWS Unscrew the nuts 14 from the coupling tie rods Take off the suction flange 1 and the cylinder 2 pulling them downwards Remove screws 12 ...

Page 38: ...vent from damaging the seals Install new parts if necessary ASSEMBLY INSTRUCTIONS 39 21 38 37 36 35 34 33 32 31 30 29 27 22 24 23 25 28 26 41 40 11 11 43 42 5 8 2 9 10 11 12 13 4 3 1 15 14 20 1 A 1 A 1 C 1 C 1 A 1 A 1 A 1 C 1 A 1 A 2 A 2 A 2 A 1 A 1 C 1 Index Instruction Description Part number A 1 PTFE grease TECHNILUB grease 10 ml 560 440 101 A 2 WEICON AS1000 grease WEICON AS1000 grease box 1 k...

Page 39: ...KREMLIN REXSON Page 38 Manual 573 199 112 SPECIFICATIONS PU 3000 PUMP model Airless ...

Page 40: ...si Proportioning ratio Fluid flow rate Refer to charts 14 15 Electrical supply of the supply unit 115V 230V 10W Air inlet connection F 3 4 BSP air inlet valve Fluid outlet connection mixer F 3 4 JIC The control box of the PU 3000 mixing machine must be installed outside the spray booth SPECIFIC PARAMETERS Parameters Description Factory adjustment Your adjustments Section of the A piston Minimum va...

Page 41: ...l 24 Clean the front part of the gun When assembling drive fluid packing 22 by pushing it from the front part to the rear part of the body 1 until the packing shoulder comes to lean against the shoulder located inside the gun Then secure the fluid packing by means of the circlip 26 Reinstall the ball needle 37 the screws 13 the seat holder assembly 17 the diaphram 9 the tip and the coupling nut 8 ...

Page 42: ...5 the seal 19 and the pin 18 Put aside the seal 13 Clean the parts check them if they are not worn or damaged Reinstall the parts in the reverse order of the disassembly sequence Cup seals Unscrew the cup nut 1 Take off the washers 3 5 Put aside the seals PTFEG seals 4a UHMW seals 4b Clean the parts check them if they are not worn or damaged Reinstall the parts in the reverse order of the disassem...

Page 43: ...ide of the cylinder to prevent from damaging the seals Install new parts if necessary ASSEMBLY INSTRUCTIONS FLUID SECTION MODEL 50cc 13 5 2 6 4 3 1 3 12 5 8 13 7 14 19 15 16 17 18 10 11 A 2 A 2 A 2 A 1 A 1 A 1 C 1 Index Instruction Description Part number A 1 PTFE grease TECHNILUB grease 10 ml 560 440 101 A 2 WEICON AS1000 grease WEICON AS1000 grease box 1 kg 2 204 lb 560 420 005 C 1 Medium streng...