Eurotec Finishing Systems Limited

Eurotec Finishing Systems Limited

Unit 4 Lockflight Buildings, Wheatlea Industrial Estate,

Wigan WN3 6XR

Phone: 01942 829 111 Fax: 01942 820 491

http://www.eurotecfinishing.com e-mail:

ER3S -U

ELECTRONIC

RECIPROCATOR

INSTRUCTION MANUAL

DOCUMENT: / ER3S-U Electronic Reciprocator - Manual
DATE ISSUED: / 20th March, 2001
ISSUE NUMBER: / 4

CAUTION

This equipment can be dangerous unless it is used in accordance with the rules laid down in this manual.

Read this manual completely before installing and operating the equipment.

Ensure all safety instructions and procedures are correctly followed and that all operators are fully trained.

IMPORTANT: All other manuals relevant to components and equipment of the installation must be followed.

CONTENTS

1. / Title
2. / Caution
3. / Contents
4. / EC Declaration of Conformity
5. / General Description
6. / Installation Instructions
7-8. / Set Up and Adjustment Instructions
9-10. / Operating Instructions
11. / Invertor Settings
12. / Routing Maintenance
13-27 / Assembly Drawings and Parts Lists

EC Declaration Of Conformity

We, Eurotec Finishing Systems Limited declare that the following product,

Description: Reciprocator

Model: ER3S-U

Use: Manipulation of Electrostatic Powder Coating Guns

was manufactured by ourselves and conforms with the following standard (s) and / or other normative document (s):

The Supply of Machinery (Safety) Regulations 1992

(S.I. 1992/3073) as amended (S.I. 1994/2063)

Signed on behalf of Eurotec Finishing Systems Ltd. by

Mr. D.H. Campbell

Technical Director

Eurotec Surface Coating Systems Limited

Unit 4 Lockflight Buildings, Wheatlea Industrial Estate, Wigan, WN3 6XR

Tel: 01942 829111 Fax: 01942 820491

V.A.T. Reg. No. 535 0123 87

Company No. 2531338 Registered In England

ER3 S-U ELECTRONIC RECIPROCATOR

GENERAL DESCRIPTION

(1) / The Reciprocator is controlled by a self contained Electronic PCB and Frequency Inverter.
(2) / Available as standard with a 1.5 M, 2.0 M or 2.5 M stroke length.
(3) / Stroke adjustment is variable via the control panel within the specified stroke length.
(4) / Pre-set override switch point limits may be internally set.
(5) / Stroke speed is variable up to 75cm/s via the control panel.
(6) / Settings are easily made and adjusted.
(7) / The reciprocator may be started/stopped remotely from an external voltage (e.g.. Eurotec system control console).
(8) / The motor stops with a controlled deceleration even under total power loss.
(9) / The reciprocator is of rugged construction and incorporates dust seals to protect the internal carriage and chain.
(10) / The floor wheels and brakes are positioned for maximum stability.
The wheels include swivel locks with 180 deg. settings.
(11) / Versatile gun support bars and clamps are available to cater for individual requirements.

INSTALLATION INSTRUCTIONS

IMPORTANT : ALL INSTALLATION WORK MUST BE CARRIED OUT BY QUALIFIED ELECTRICIAN

The following instructions are for the installation of an ER3S-U Reciprocator.

Full schematic wiring diagrams and connector diagrams are shown at the back of this manual.

(1) / Position the ER3S-U Reciprocator away from all obstructions ensuring that the carriage, guns, bars and hoses are free to travel their full stoke without interference.
Apply the floor brakes.
(2) / Ensure that the power switch on the Reciprocator is set to the "0" (off) position.
(3) / Ensure that the "Mains Selector" switch inside the control unit is set to the correct supply voltage. The control unit is found on the rear of the reciprocator column, its interior is accessed by releasing two screws on the vertical face of the box.
NOTE: Extreme caution should be used when the control unit is open, live terminals are accessible.
(4) / Referring to "Schematic Diagram - ER3S-U Reciprocator" make the following connections to the control unit on the rear of the Reciprocator:
1) Mains Supply Lead (Pt. No. 4065055) to the three way & earth Supply Plug.
2) Trigger Lead (Pt. No. 4068022) to the seven way Control Socket.
NOTE: The Trigger Lead is only connected when remote triggering of the Reciprocator is required.
(5) / Connect the other end of the Mains Supply Lead (Pt. No. 4065055) to 240v 50/60Hz mains supply fused at 25A. The supply may be either 220-240v single phase or derived from two phases of a 220-240v three phase supply.
NOTE: The mains lead is colour coded as follows:
Live - L - Brown
Neutral - N - Blue
Earth - E - Green / Yellow
IMPORTANT: The Earth (grounding wire) contact must be made.
(6) / If the Trigger Lead is to be used connect its other end to the Robot 1 (or 2) connector on the Eurotec System Control Unit (SCU).
(7) / Ensure that the following settings are made on the control unit:
1) The Supply Switch is set to the "Off" (0) position.
2) The Emergency Stop Switch is not activated (twist the body clockwise to reset).
3) The Stop / Start Switch is set to the "Off" (0) position. The Stop / Start Switch is denoted by a double headed arrow.
4) The Inhibit Switch is set to the "Run" position.
5) The Speed Potentiometer is set to minimum (0%) by turning fully anticlockwise.
6) The Bottom Position Potentiometer is set to 30%
7) The Top Position Potentiometer is set to 70%
(8) / Unless the machine is to be "Set Up and Adjusted" immediately, close and secure the cover on the control unit.

SET UP AND ADJUSTMENT INSTRUCTIONS

IMPORTANT WARNING:- THESE MACHINES ARE FITTED WITH A POWERFUL AC ELECTRIC MOTOR WHICH IS CAPABLE OF DELIVERING A VERY HIGH FORCE, EVEN WHEN TRAVELLING AT VERY LOW SPEED.

TO AVOID INJURY PERSONNEL MUST BE PREVENTED FROM COMING INTO CONTACT WITH MOVING PARTS.

The maximum permissable stroke of the machine should be set as described below to prevent the carriage or guns from travelling beyond the confines of the spray booth opening. If this is not done, the reciprocator could be overturned or the guns or spray booth and its services damaged.

If the motor is stalled for any reason, the inverter will "trip out" to prevent damage or burn out of the motor. If this happens, the main switch on the control unit must be turned off for fifteen seconds and then on again to reset the Reciprocator.

If the machine is run at very low speeds, the cooling effect of the motor fan will be reduced causing the motor to overheat. This will also cause the inverter to "trip out". Reset as above.

To stop the machine in an emergency, press the Emergency Stop push-button switch on the control unit at the rear of the machine. This will rapidly stop the motor. The switch will latch closed and must be twisted to reset.

(1) / Mount the gun support bars and automatic spray guns into position on the carriage of the reciprocator. Connect HT. cables , airlines and powder hoses as required.
(2) / Support the HT. cables , airlines and powder hoses in the flexible conduit ensuring that the carriage may travel full stroke without pulling the cables.
(3) / Ensure that there are no obstructions which may catch or interfere with the carriage, flight bar or spray guns, if it were to travel its full available stroke.
(4) / Ensure all electrical connections are made as described in the installation instructions.
(5) / Ensure that all switches and potentiometers are set as described in the installation instructions.
NOTE: The inverter is pre-programmed. To prevent the Reciprocator "crashing" the values set must not be altered.
(6) / Release the cover of the control unit by freeing the two screws on its vertical face.
NOTE: When the cover is released extreme caution must be exercised, live terminals are accessible within the control unit.
(7) / Turn the Supply Switch on the control unit to the "1" (on) position.
(8) / Turn the Stop / Start switch to the "1" (on) position.
(9) / Slowly turn the "Speed" control potentiometer clockwise. The carriage should start to travel upwards until it reaches seventy percent of its maximum pre-set height at which point the carriage will reverse and travel downward. At thirty percent of the pre-set minimum height the carriage will change direction again and travel upward.
NOTE: When switched on ,immediately after the mains switch is turned "ON", the carriage should always start to travel upward. If this does not happen and the carriage travels down toward the bottom stop, switch the power off to the Reciprocator and wait fifteen seconds before opening the inverter case. Reverse two of the three output phases on the inverter (the output phases are terminals U,V & W). Close the inverter box and start again at step 5.
(10) / With the Reciprocator running at maximum speed slowly turn the position potentiometers toward their extreme settings i.e. top position to maximum and bottom position to minimum. As the position potentiometers are adjusted the carriage is seen to approach its maximum stroke. If the carriage approaches within 100mm of either end-stop stop adjusting the position potentiometers and adjust the over-ride trim-pots inside the control unit. The position potentiometers may now be adjusted to full stroke. The procedure for altering the trim-pots is described next.
(11) / The extreme travel limit's of the Reciprocator carriage are pre-set to the maximum stroke. If these limits are too great for the spray booth opening they must be re-set to prevent the carriage crashing. A minimum 100mm safety margin must be left between the top and bottom of the booth opening and the carriage travel limits (including all mounting bars, hoses and cables). Inside the control unit locate the position trim-pots on the PCB these are marked TOP and BOT..
(12) / Before adjusting the extreme limits set the Speed pot. on the front of the control unit to maximum and mount guns, mounting bars, etc. in position. Setting Speed to maximum allows the Reciprocator to be set for maximum over-shoot. Mounting the guns etc. enables the operator to ensure that they will not interfere with the booth.
Note: The Top Position must be set to 100% and the Bottom Position to 0%
(13) / Using a trim-pot tool carefully adjust the trim-pots marked "TOP" & "BOT". Each switch point must be set to allow 100mm between the carriage, guns, bars etc. and the booth opening.
NOTE: For each trim-pot turning the screw clockwise moves the switch point toward the centre of the stroke effectively shortening the stroke. Turning the screw anti-clockwise lengthens the stroke.
Note: Adjusting one switch point will slightly alter the other point. Once both points have been set they both need to be checked and possibly slightly readjusted.
(14) / When the over-ride stroke is set close and secure the control unit cover.
(15)

NOTE: The position potentiometer is set to read 2.5k at the mid-stroke of the carriage when disconnected from the positioning PCB. If the reading at mid stroke varies greatly from this then the carriage and potentiometer may need to be reset.

The machine is now ready for use. Before doing so read and follow the "Operating Instructions".

OPERATING INSTRUCTIONS

IMPORTANT WARNING

These machines are fitted with a powerful AC electric motor which is capable of delivering a very high force, even when travelling at very low speed.

TO AVOID INJURY PERSONNEL MUST BE PREVENTED FROM COMING INTO CONTACT WITH MOVING PARTS.

The maximum permissable stroke of the machine should be set as described in the "Set up and Adjustment" instructions to prevent the carriage or guns from travelling beyond the confines of the spray booth opening. If this is not done, the reciprocator could be overturned or the guns or spray booth and its services damaged.

Reciprocator Control Panel

The Reciprocator is operated via a control panel on the rear of the machine. The panel consists of a supply switch, start / stop switch, inhibit switch, emergency stop, speed control potentiometer and two position control potentiometers. The control potentiometers allow the speed and stroke switch points to be altered.

Entering Parameters

The position control potentiometers are used to set a percentage (0 - 100) of the maximum pre-set stroke. The speed control potentiometer sets a percentage (0 - 100) of the maximum speed (75cm/s)

Reciprocator Operation

(1) / Ensure the extreme stroke limits have been set to prevent the Reciprocator and associated equipment crashing into the booth (Set-up and Adjustment Instructions)
Ensure all connections are correctly made (Installation Instructions)
(2) / Switch power on to the Reciprocator (supply switch on the control unit).
NOTE: Before switching power on set the start / stop switch to stop (0) otherwise the machine will commence operation immediately. The start / stop switch is denoted by a double headed arrow.
(3) / For first time operation ensure that the speed potentiometer is turned to minimum. Once operators are familiar with the Reciprocator the control unit may be switched on without turning the speed down.
(4) / Ensure the Emergency Stop and inhibit switches are correctly set (Installation Instructions).
(5) / Turn the start / stop switch to start (1).
(6) / Slowly turning the Speed potentiometer up allows the carriage to start moving upward. When the carriage reaches its Top position the carriage will reverse and travel to the bottom position.
Further adjustment of the Speed Potentiometer increases the speed.
Set the speed to the desired setting.
(7) / Next adjust the position potentiometers so that the carriage strokes the required distance.

The Reciprocator should be adjusted to suit product size and conveyor speed.

IMPORTANT:-

When altering settings, care must be taken not to set high velocity between close switching limits. If this is done then a degree of control may be lost and the reciprocator crash.