DÖRR EcoDose 2K User manual

LEADING IN PRODUCTION EFFICIENCY
www.durr.com
OPERATING MANUAL
MDR00003EN
Material number: N10100003V
Release : 10
Date : 25.05.2020
EcoDose 2K
Operating Manual

Operating Manual
© Dürr Systems AG
ED2K N10100003V – Operating Manual Rev10LD EN. docx
Rev.10 – 25.05.2020
2
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
Manufacturer: Dürr System AG
Application Technology
Carl-Benz Str. 34
74321 Bietigheim-Bissingen
Germany
Telephon: [phone]
Internet: www.durr.com
Revision Status
Quality Assurance System is responsible to maintain updated this document in its last
version applicable.
Version / Changes
Version of this document: 10 dated 25.05.2020
Story of version / changes:
Version Date Revision description
00
26.02.2015
Emission
01 03.04.2015
General revision. Detailed description of SW functioning by
visualization of touch screen pages.
02 18.10.2015
Modified system of safety issues description with new layout
of pages.
03 13.07.2016
General revision with comments and notes by site operators
during installation.
04 02.12.2016
Modified drawings and schemes of the manual according
latest version of components and assembly.
05 05.05.2017 Added “closed loop” functioning description and setting of
parameters.
06 14.10.2018 Added attachments into body of Operating Manual with
references.
07 11.03.2019
Improvement of separated version description and Atex
definitions. Detailed grounding connection of Fluidic Panel
in “separated version”. Detailed Coriolis flow meter
calibration process.
09
04.03.2020
Changed wiring diagram revision
10 25.05.2020
Updated drawings and revised technical norms (new
versions)

Operating Manual
© Dürr Systems AG
ED2K N10100003V – Operating Manual Rev10LD EN. docx
Rev.10 – 25.05.2020
3
The reproduction, distribution and utilization of this document as well as the
communication of its contents to others without explicit authorization is prohibited.
Offenders will be held liable for the payment of damages

Operating Manual
© Dürr Systems AG
ED2K N10100003V – Operating Manual Rev10LD EN. docx
Rev.10 – 25.05.2020
4
TABLE OF CONTENTS
1 Introduction................................................................................................. 07
1.1 How to Use this Document..................................................................................... 07
1.2 Terminology.............................................................................................................. 07
1.3 Explanation of Safety Notes and Signs................................................................. 07
2 Technical Data............................................................................................. 09
2.1 Range of Application and Intended Use ............................................................... 09
2.2 Key Data.................................................................................................................... 11
2.3 Version ...................................................................................................................... 12
2.4 Determination of the Ex Zones............................................................................... 14
2.5 Associated Documents ........................................................................................... 16
2.6 Normative Requirements…………………………………… …………………. 17
3 Safety........................................................................................................... 18
3.1 Addressees for this Manual.................................................................................... 18
3.2 Use of Tools in Ex Zones ........................................................................................ 19
3.3 Basic Information on Safety Notes ........................................................................ 20
3.4 Troubleshooting Instructions.................................................................................. 20
3.5 Special Safety Notes ............................................................................................... 20
3.6Plate data. (example)............................................................................................... 21
4 Transport and Storage................................................................................ 22
4.1 Transport................................................................................................................... 22
4.2 Storage...................................................................................................................... 23
5 Description and operation.......................................................................... 24
5.1 General Description................................................................................................. 24
5.1.1 Remote magnetic switch panel .................................................................. 25
5.2 Operating principle.................................................................................................. 26
5.3 Design of the Modules ............................................................................................ 28
6 Installation instructions .............................................................................. 29
6.1 Electrical connections ............................................................................................. 29
6.2 Pneumatic connections........................................................................................... 30
6.2.1 Compressed air specifications ................................................................... 30
6.2.2 Pneumatic connections ............................................................................... 31
6.3Product connection IN ............................................................................................ 32
6.4 Product connection OUT ........................................................................................ 34
7 Commissioning ........................................................................................... 35
7.1 Startup....................................................................................................................... 35

Operating Manual
© Dürr Systems AG
ED2K N10100003V – Operating Manual Rev10LD EN. docx
Rev.10 – 25.05.2020
5
7.2 System configuration............................................................................................... 35
7.3 Management of PLC alarms for consumable components................................ 36
8 Operations................................................................................................... 37
8.1 Overview controls.................................................................................................... 37
8.2 Operative modes...................................................................................................... 38
8.3 Visualization.............................................................................................................. 39
8.4 Browsing windows ................................................................................................... 41
8.4.1 System page ................................................................................................. 41
8.4.2 Cycle program page .................................................................................... 43
8.4.3 Parameters page.......................................................................................... 43
8.4.4 Pre-purge and purge cycle page............................................................... 47
8.4.5 Active alarm page ........................................................................................ 47
8.4.6 Alarm history page....................................................................................... 48
8.4.7 Consumption page....................................................................................... 48
8.4.8 External control interface signal page....................................................... 49
8.4.9 Calibration data page................................................................................... 49
8.4.10 User management page............................................................................ 50
8.4.11 Reset passwords page.............................................................................. 50
8.4.12 Settings page.............................................................................................. 51
8.5 Description and operation of each visualization window ................................... 52
8.5.1 System page functions................................................................................ 52
8.5.1.1 Switching the operating modes.................................................... 52
8.5.1.2 Language switching........................................................................ 54
8.5.1.3 User administration ........................................................................ 55
8.5.1.4 Date and time setting ..................................................................... 57
8.5.1.5 Data backup to USB storage......................................................... 58
8.5.1.6 USB Data Save/Load Operations................................................. 59
8.5.1.7 Screen cleaning .............................................................................. 61
8.5.1.8 Change passwords......................................................................... 62
8.5.1.9 Reset passwords............................................................................. 63
8.5.1.10 Change IP address....................................................................... 64
8.5.1.11 Change calibration data............................................................... 66
8.5.1.12 Lamp test ....................................................................................... 67
8.5.2 Cycle programs – recipe selection............................................................ 68
8.5.2.1 Cycle programs............................................................................... 68
8.5.2.2 System status list............................................................................ 72
8.5.2.3 Relay external signal system ready.............................................. 72
8.5.2.4 Recipe selection.............................................................................. 73
8.5.3 Spray – valves............................................................................................... 74
8.5.3.1 Status indicator valves ................................................................... 75
8.5.3.2 Manual control valves .................................................................... 76
8.5.4 Spray data…………………………………………………………………… 77
8.5.5 Recipes data ................................................................................................. 78
8.5.6 Pre-purge, purge program.......................................................................... 79
8.5.6.1 Pre-purge......................................................................................... 80
8.5.6.2 Purge ................................................................................................ 80
8.5.7 Consumption................................................................................................. 81

Operating Manual
© Dürr Systems AG
ED2K N10100003V – Operating Manual Rev10LD EN. docx
Rev.10 – 25.05.2020
6
8.5.8 Parameters.................................................................................................... 82
8.5.9 Alarms windows ........................................................................................... 91
8.5.9.1 Actual alarms................................................................................... 91
8.5.9.2 Alarm history ................................................................................... 92
8.6 Messages and alarm groups.................................................................................. 93
8.7 External recipe mode .............................................................................................. 102
8.8 External control interface........................................................................................ 103
8.8.1 Outputs to external control interface......................................................... 103
8.8.2 Inputs from external control interface ....................................................... 106
8.9 Example interface flowchart ................................................................................... 108
8.10 UDP connection EcoDose and external control .................................................. 110
8.11 Closed loop flow regulation.................................................................................... 111
8.12Remote magnetic switch panel.............................................................................. 120
8.12.1 Available commands ................................................................................. 120
8.12.2 Recipe change + / -and confirm ........................................................... 121
8.12.3 Pot-life lamp................................................................................................ 121
8.13 Remote EcoPUC A RA BUS panel ....................................................................... 122
8.13.1 Main menu .................................................................................................. 122
8.13.1.1 Manu actual parameters.............................................................. 123
8.12.1.2. Menu nominal parameters ......................................................... 124
9 Maintenance................................................................................................ 126
9.1 Electrical panel......................................................................................................... 127
9.2 Fluidic Panel ............................................................................................................. 128
10 Parts List ..................................................................................................... 131
11 Available Documents.................................................................................. 132
12 Contacts & Hotlines .................................................................................... 133

Operating Manual
© Dürr Systems AG
ED2K N10100003V – Operating Manual Rev10LD EN. docx
Rev.10 – 25.05.2020
7
1 Introduction
This document is intended for the assembly, operating and directing and
maintenance personnel.
Everyone implied in operation, maintenance and repair must have read and
understood this document – especially the texts marked with the safety
symbol. This document should always be at the disposal of personnel.
Attached to this document there are drawings, parts lists, manuals of the main
components that should be used for more information.
This manual reflects the state of the machine, at the time of input on the market
and it is subject to amendment, at the sole discretion of Dürr Systems AG.
In case of amendments to the manual for further similar machines, Dürr
Systems AG does not undertake to update the manuals for equipment already
on the market.
Dürr Systems AG will refuse any liability for damages arising from the non-
observance of the manual!
For any question, please contact either our service or spare parts
departments, or one of Dürr Systems AG subsidiaries of (see chapter 12
“Contacts & Hotline”).
1.1 How to Use this Document
In this manual, you will find all the necessary information, specifications and
warning notes for assembly, operating and maintenance operations.
A T T E N T I O N
Read this manual and the attached documents attentively.
Respect the specifications therein contained
.
1.2 Terminology
The terms used in this manual are supposed to facilitate an easy and quick
comprehension of the text.
1.3 Explanation of Safety Notes and Symbols
In this manual, symbols and signal words are used to indicate specific dangers.
Symbols are integrated with a text. This text describes the danger and explains
how to avoid it. Furthermore, the necessary precautions are specified.

Operating Manual
© Dürr Systems AG
ED2K N10100003V – Operating Manual Rev10LD EN. docx
Rev.10 – 25.05.2020
8
It is assumed that before performing the operations therein described, the
operator has fully understood the entire manual and knows its contents.
The sole observance of safety notes is by no means sufficient.
Dangers to life and limb
The red safety note "Danger" indicates a high risk that will result in death or a
severe injury
D A N G E R
Danger of lethal injuries
The orange safety note "Warning" indicates a medium risk that could result in
death or a severe injury
W A R N I N G
Danger of severe injuries
The yellow safety note "Caution" indicates a low risk that could result in an
insignificant or minor injury
C A U T I O N
Danger of minor injuries
Dangers for the production and the operation
If the jobs therein described in are not carried out correctly or unsuited tools
or materials are used, a major breakdown may jeopardize the entire
production and the normal course of operations. Such breakdowns may be
very expensive.
Such dangers are referred to with the blue note "Attention.
A T T E N T I O N
Danger of material damage and production interference

Operating Manual
© Dürr Systems AG
ED2K N10100003V – Operating Manual Rev10LD EN. docx
Rev.10 – 25.05.2020
9
2 Technical Data
2.1 Range of Application and Intended Use
Product description:
EcoDose 2K (ED2K) is a machine designed for dosing and mixing fluid
components (typically bases and catalyst) according to pre-defined ratios.
It is intended to be used in all applications based on “two components”
process, in which two liquids, base and catalyst, are mixed together to have a
chemical reaction to reach the final state suitable to cover surfaces in general.
Typically, ED2K is used in painting process of any kind, and in every surface
protecting process by spraying liquid materials.
It can be used in manual application and in automatic application; in this case
it communicates with any kind of PLC/PC controlled device, with Ethernet
interface, and allows a complete automated functioning, including of
safety/alarms management, interchange of relevant process data, 4.0 industry
compliance.
The machine is complete of a base plate, a main support, an electrical cabinet,
a pneumatic cabinet, a fluidic panel. Mixing of fluids is performed into the
fluidic panel, using flow meters, pneumatic valves, static mixing devices.
According to type of flow meters used, are available two versions, with Coriolis
flow meters and with Gear flow meters, each of them in high pressure or low
pressure. EcoDose 2K was built exclusively for use in the field of surface finish
or similar activities
EcoDose should be installed, maintained and repaired only by persons who
know the equipment very well and have been made aware about the dangers.
The main rules for the prevention of accidents must be respected, as well as
the rules for safety.
The commands of EcoDose 2K have been designed exclusively for the
activity of dosing components with the mixing machinery EcoDose 2K.
The password to change the input parameters has to be provided only to
trained personnel.
Use EcoDose 2K only for products that are compatible with its components.

Operating Manual
© Dürr Systems AG
ED2K N10100003V – Operating Manual Rev10LD EN. docx
Rev.10 – 25.05.2020
10
Coriolis Version
Remote magnetic switch
panel
(optional )
Gear Version
D A N G E R
EcoDose 2K
in “stand alone” version can
not be installed in areas with
potentially explosive atmospheres
, please see “separated
version” for
fluidic panel installation into Ex areas.
Grounding
The metal parts of the plants subject to contact with people who for lack of insulation or
other causes may be energized, must be grounded. In this regard, on the base of the
machine there is a point of contact identified by an adhesive (see drawing) for the
connection with the network of general grounding of establishment.