DÖRR EcoDose 3K User manual

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Operating Manual
© Dürr Systems AG
ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx
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OPERATING MANUAL
EcoDose 3K
MDR00005EN
Material number: N10110001V
Release : 02
Date : 03.07.2020
EcoDose 3K
Operating Manual

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Operating Manual
© Dürr Systems AG
ED3K_Operating_Manual_Rev02LD_03Lug2020_EN. docx
Rev.02 – 03.07.2020
TRANSLATION OF THE ORIGINAL
INSTRUCTIONS
Manufacturer: Dürr System AG
Application Technology
Carl-Benz Str. 34
74321 Bietigheim-Bissingen
Germany
Telephone: [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: 02 dated 03.07.2020
Story of version / changes:
Version Date Revision description
00 26.02.2019 Emission
01 03.04.2019 General revision. Detailed description of SW
functioning by visualization of touch screen pages.
02 03.07.2020
Updated drawings and revised technical norms
(new versions)
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

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TABLE OF CONTENTS
1Introduction....................................................................................................................................... 6
1.1 How to Use this Document...................................................................................................... 6
1.2 Terminology............................................................................................................................. 6
1.3 Explanation of Safety Notes and Symbols.............................................................................. 7
2Technical Data ................................................................................................................................. 8
2.1 Range of Application and Intended Use.................................................................................. 8
2.2 Key Data.................................................................................................................................. 9
2.3 Version .................................................................................................................................. 10
2.4 Determination of the Ex Zones.............................................................................................. 12
2.5 Associated Documents.......................................................................................................... 14
2.6 Plate data .............................................................................................................................. 15
2.7 Normative Requirements....................................................................................................... 16
3Safety............................................................................................................................................. 17
3.1 Addresses for this Manual........................................................................................................... 17
3.2 Use of Tools in Ex Zones............................................................................................................ 18
3.3 Troubleshooting Instructions....................................................................................................... 18
3.3.1 Special Safety Notes............................................................................................................. 19
4Transport and Storage................................................................................................................... 20
4.1 Transport............................................................................................................................... 20
4.2 Storage.................................................................................................................................. 21
5Description and operation.............................................................................................................. 22
5.1 General Description............................................................................................................... 22
5.1.1 Remote magnetic switch panel ......................................................................................... 23
5.2 Operating system .................................................................................................................. 24
5.3 Design of the Modules........................................................................................................... 26
6Assembly Instructions.................................................................................................................... 27
6.1 Electrical connection.............................................................................................................. 27
6.2 Pneumatic Connections ........................................................................................................ 28
6.2.1 Compressed air specifications .......................................................................................... 28
6.2.2 Pneumatic connection....................................................................................................... 29
6.3 Product connection IN........................................................................................................... 30
6.4 Product connection OUT....................................................................................................... 32
7Commissioning............................................................................................................................... 33
7.1 Starting .................................................................................................................................. 33
7.2 System configuration............................................................................................................. 33
7.3 Alarms management on PLC for consumable components.................................................. 34
8Operation........................................................................................................................................ 35
8.1 Controls overview.................................................................................................................. 35

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8.2 Operative modes................................................................................................................... 35
8.3 Visualization .......................................................................................................................... 37
8.4 Browsing windows................................................................................................................. 39
8.4.1 System page...................................................................................................................... 39
8.4.2 Cycle program page.......................................................................................................... 41
8.4.3 Parameters pages............................................................................................................. 41
8.4.4 Pre-purge and purge cycle page....................................................................................... 45
8.4.5 Active alarm page.............................................................................................................. 45
8.4.6 Alarm history page............................................................................................................. 46
8.4.7 Consumptions page (button located in spray data page).................................................. 46
8.4.8 External control interface signal page............................................................................... 47
8.4.9 Calibration data page ........................................................................................................ 47
8.4.10 User management page................................................................................................ 48
8.4.11 Reset passwords page.................................................................................................. 48
8.4.12 Settings page................................................................................................................. 49
8.5 Description and operation of each visualization window....................................................... 50
8.5.1 System page functions...................................................................................................... 50
8.5.2 Cycle programs – recipe selection.................................................................................... 64
8.5.3 Spray - valves.................................................................................................................... 68
8.5.4 Spray data ......................................................................................................................... 71
8.5.5 Recipes data...................................................................................................................... 72
8.5.6 Pre-purge, purge program................................................................................................. 73
8.5.7 Consumption ..................................................................................................................... 75
8.5.8 Parameters........................................................................................................................ 76
8.5.9 Alarms windows................................................................................................................. 84
8.6 Messages and alarm groups................................................................................................. 86
8.7 External recipe mode............................................................................................................. 95
8.8 External control interface....................................................................................................... 96
8.8.1 Outputs to external control interface ................................................................................. 96
8.8.2 Input from external control interface.................................................................................. 99
8.9 External interface flowchart................................................................................................. 101
8.10 UDP connection EcoDose and external control.................................................................. 103
8.11 Closed loop flow regulation................................................................................................. 104
8.11.1 Regulator page............................................................................................................ 105
8.11.2 Regulation table data................................................................................................... 107
8.11.3 Graphic representation................................................................................................ 109
8.11.4 Regulation parameters................................................................................................ 110
8.11.5 External interface signal.............................................................................................. 112
8.12 Remote magnetic switch panel ........................................................................................... 113
8.12.1 Available commands ................................................................................................... 113
8.12.2 Recipe change + / - and confirm ................................................................................. 114

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8.12.3 Pot life lamp................................................................................................................. 114
9Maintenance................................................................................................................................. 115
9.1 Control panel....................................................................................................................... 116
9.2 Fluidic panel ........................................................................................................................ 117
10 Parts List.................................................................................................................................. 120
10.1 Drawings.............................................................................................................................. 120
11 Attached documents................................................................................................................ 121
12 Contacts & Hotline................................................................................................................... 121

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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.

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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.
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
D A N G E R
Danger of lethal injuries
The red safety note "Danger" indicates a high risk that will result in death or a
severe injury.
W A R N I N G
Danger of severe injuries
The orange safety note "Warning" indicates a medium risk that
could result in death or a
severe injury.
C A U T I O N
Danger of minor injuries
The yellow safety note "Caution" indicates a low risk that could
result in an insignificant or minor injury.
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 mayjeopardize 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

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2 Technical Data
2.1 Range of Application and Intended Use
EcoDose 3K was built exclusively for use in the field of surface finish or similar activities.
EcoDose 3Kshould 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 3K have been designed exclusively for the activity of dosing
components with the mixing machinery EcoDose 3K.
The password to change the input parameters has to be provided only to trained personnel.
Use EcoDose 3K only for products that are compatible with its components.
Coriolis version
Remote magnetic switch
panel
(optional )
Gear version
D A N G E R
Eco
Dose 3K can not be installed in areas with potentially explosive
atmospheres. In remoted option Fluidic Panel can be installed in Atex
Zone 2
only.

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2.2 Key Data
Dimensions in mm.
Coriolis version
Dimensions in mm.
Gear version
Product temperature
min 15°C max 40°C
Air inlet pressure
5,5 a 8 bar
Mixing ratio (variable)
da 1:0 a 30:1
Max. pressure in/out (with
low
pressure c. c. valves)
20 bar
Max. pressure in /out (with high pressure c. c. valves and gear)
200 bar
Max. pressure in /out (with high pressure c. c. valves and Coriolis)
160 bar
Ambient temperature, transport and storage temperature da 10°C a 40° C
Power supply
100-240 Vac
Frequency
50 - 60 Hz
Breaking capacity 14kA
Rated Power
130W
Power consumption Coriolis
92W
Power consumption Gear
60W
Current consumption Coriolis
0,4A
Current consumption Gear
0,26A
Degree of protection
IP55
Weight Coriolis version
Round 230 kg
Weight Gear version
Round 190 kg
Flow Range: Obtainable flow range of mixed product varies in function of mixing ratio, type and size
of flow meters, viscosity of the product, temperature of the product, etc. As general indication it could
be defined a minimum limit of flow of mixed product of 50 cc/min. This indication has to be confirmed
and defined case by case during commissioning and set-up of the machine in real conditions with real
products.

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2.3 Version
Gear Flow Control
Gear Flowmeter A,B or C
type 1
: 0,005-2 lt.
5cc-2000cc
type 2
: 0,02-3 lt.
20cc-3000cc
GFM
A GFM B GFM C Volume Flow Range Mixing ratio Range Range
Viscosity A CPS
Range
Viscosity B - C
CPS
1 1 1 30cc / 1200 cc * 1:1 to 30:1 25-350 25-350
2 1 1 40cc / 2200cc ** 1:1 to 30:1 25-500 25-350
2 2 2 130cc / 3200cc *** 1:1 to 30:1 25-500 25-500
* For Mixing Ratio range
5:1 to 10:1 volume flow range will be 60cc/1200cc.
** For Mixing Ratio range
5:1 to 10:1 volume flow range will be 60cc/2600cc.
*** For Mixing Ratio range
5:1 to 10:1 volume flow range will be 160cc/3400cc.
Color change block valves : Low or high Pressure
n. color with L.P. valves
:
2 or 4 or 6 or 8 or 10
n. color with H.P. valves
:
1 or 3 or 5 or 7 or 9
n. hardener
:
1 or 3
n. gun
:
1 or 2
n. EcoGun Cleaner M
:
1 or 2
n. Low Pressure Regulator Flow
:
1 or 2

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Coriolis Flow Control
Coriolis Flowmeter A,B or C
type 1
Volume
Flow Range Mixing ratio Range Range Viscosity A CPS Range Viscosity B - C CPS
40cc / 3400cc 1:1 to 30:1 20-500 20-500
Color change block valves : Low or high Pressure
n. color with L.P. valves
:
2 or 4 or 6 or 8 or 10
n. color with H.P. valves
:
1 or 3 or 5 or 7 or 9
n. hardener
:
1 or 3
n. gun
:
1 or 2
n. EcoGun Cleaner M
:
1 or 2
n. Low Pressure Regulator Flow
:
1 or 2

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2.4 Determination of the Ex Zones
Option : Stand Alone
1 Flow control
7 Air manifold
2
Color change valves
8
Air filter
3
Filter product
9
Static Mixer
4
Pumping unit
10
Spray gun
5
Manual valve
11
EcoGun Cleaner M
6
Air regulator
12
Remote magnetic switch panel
(optional)
A T T E N T I O N
During normal operation, an explosive atmosphere is present only inside the
spray booth

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Option : Separated
1
Flow control
7
Air manifold
2
Color change valves
8
Air filter
3
Filter product
9
Static Mixer
4 Pumping unit 10 Spray gun
5
Manual valve
11
EcoGun Cleaner M
6
Air regulator
12
Remote magnetic switch panel
(optional)
A T T E N T I O N
During normal operation, an explosive atmosphere is present only inside the
spray booth

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2.5 Associated Documents
A T T E N T I O N
Besides the observance of safety instructions therein described, as far as transport
operations, installation, normal functioning and maintenance are concerned, also refer to the
instructions contained in the manuals of the equipment connected to
EcoDose 3K.
For example:
- Filter product
- Pumping unit
- Manual valve
- Air regulator
- Air manifold
- Air filter
- Spray gun
- EcoGun Cleaner M

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2.6 Plate data
Atex marking of Fluidic Panel:

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2.7 Normative Requirements
Below is the table with the directives and regulations for the complete machine and just for the Fluidic
Panel :
Complete machine declaration :
Machinery Directive 2006/42/EC
Low Voltag Directive2014/35/EC
Electromagnetic Compatibility Directive 2014 / 30 / CE
Regulations:
UNI EN ISO 12100:2010 Safety of machinery- General principles for design- Risk
assessment and risk reduction
EN 60204:2016
Electrical equipment of machines
EN 60204-1 Safety machinery- Electrical equipment of machines
EN 62061;2005/A1 :2013 Safety of machinery- Functional safety of safety - related
electrical, electronic and programmable electronic control
systems
IEC 61439
General rule on electrical cabinets.
UNI EN ISO 13849-1:2016 Safety of machinery - Parts of the safety-related control systems
- Part 1: General design principles
UNI EN ISO 13857:2020
Safety of machinery - Safety distances to prevent reaching
hazard
zones
with upper and lower limbs
UNI EN ISO 13854:2020
Machinery Safety -
Minimum spaces to prevent crushing of body
parts
UNI EN ISO 13850:2015
Machinery Safety - Emergency Stop - Design Principles
Fluidic Panel declaration :
We, herein signers, declare on our own responsibility, that the components comply with the provisions
of the Directive 2014/34 / EU (ATEX Directive) and can be classified as follows:
II 3G Ex h IIA T6 Gc
Regulations:
EN 60079-0:2018
Explosive atmospheres Part 0: Equipment
- General
requirements.
EN 60079-14:2014
Explosive atmospheres Part 14: Equipment - Design, choice and
installation of electrical systems

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3 Safety
3.1 Addresses for this Manual
It is therein assumedthat only authorized, experienced personnel will perform installation,operating
and maintenance activities.
The activities therein described may only be carried out by:
- sufficiently qualified personnel [1] for the operations to be carried out,
- particularly trained personnel [2] for the operations to be carried out,
- personnel having knowledge of the possible dangers
- personnel having knowledge of the applicable safety regulations.
The installation, maintenance and repair of EcoDose 3K can only be carried out by experienced
personnel [3]. An adequate advanced training or qualification of the personnel i has to be regularly
performed.
[1] Therein meaning authorized, experienced and suited
[2] Therein meaning trained and experienced
[3] Qualification of operational personnel for jobs in explosive areas:
- knowledge of general principles for the protection from explosions;
- knowledge of general principles of the types of protection and the designation of protective
devices;
- broad knowledge of inspection, maintenance and repair requirements in potentially explosive
areas according to IEC 60079 -17
If a precise assignment of responsibilities is necessary, this operating manual distinguishes
between:
- Customer (management, operations manager, installation manager or a comparable function
in the enterprise)
- Operator (installation operator, maintenance personnel, programmer, fitter and cleaner or a
comparable function in the enterprise).
The customer must ensure that the operator’s tasks and responsibilities have been clearly defined.
The customer must ensure that every operator has been informed and instructed about all
dangers. The customer must provide the operator with the necessary protective equipment. Each
operator must have been informed and instructed about safety functions and safety equipment.
The operator may only carry out the installation, commissioning, maintenance, repair and cleaning
activities expressly described in this operating manual. All the operations not described in this
manual can only be carried out by the manufacturer. For all maintenance, repair and cleaning
activities, you must observe the industrial safety regulations applicable at the place of the
installation

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3.2 Use of Tools in Ex Zones
The spray booth is classified once into ex zones according to UNI EN 16985:2019. Ex zones are
defined beforehand and are effective independently of the installation's operating condition. Even
a sufficiently ventilated spray booth which does not contain any inflammable material is still
considered as ex zone.
According to DIN EN 50176, only accessories meeting the requirements of EN 60079-0 and/or
EN13463-1 can be used in an ex zone.
UNI EN 16985:2019 always requires a technical ventilation inside the spray booth. Spray booths
with fresh air inlets are provided a sufficient ventilation after 3 to 10 air exchanges. As a rule, the
spray booth is sufficiently ventilated after 5 minutes. In air recirculation installations, a ventilating
time of 30 minutes [4] is necessary to achieve a sufficient ventilation, depending on the mixture
ratio of recirculating air to fresh air.
The use of not classified tools pursuant to the regulations for protection against explosions in
hazardous areas is the customer's exclusive responsibility.
- The customer has to carry out a risk assessment for every operation performed, to document
them and to prepare an operating manual on the basis of the resulting evaluation.
- The customer has to ensure that all operators carrying out their own respective tasks know
and observe these measures.
[4] This value is dependent on the design and settings and must always be determined on the basis
of the system-specific parameters.
3.2.1 Basic Information on Safety Notes
A T T E N T I O N
General dangers relative to the plant where
EcoDose 3K is goin
g to be installed are not
expressly referred to in this manual. The personnel must be informed by the customer
and correspondingly trained on these dangers.
You must also observe the information in chapter 2.5"Associated Documentation".
In this operating manual, you will only find the safety notes specifically concerning the product
described in this manual.
For the activities therein described, it is an indispensable requirement for the user of this operating
manual to know and observe the additional installation documentation and safety notes.
Furthermore, the user of this manual must pay attention to and observe effective health and safety
regulations in the place of operation.
The meaning of the symbols used in our operating manuals has been explained in chapter 1
"Introduction".
3.3 Troubleshooting Instructions
Repairs can only be carried out by specifically trained personnel, otherwise any warranty from Dürr
Systems GmbH will be invalidated.
Faults, their cause and their rectification have to be specifically recorded.

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3.3.1 Special Safety Notes
Before performing maintenance and repairs you must make sure that EcoDose 3K does not
contain any residual pressure (air and product).
W A R N I N G
Danger due to spraying or
splashing material!
Potential chemical burns of the skin due to material spurting from defective paint pipes
and color changers.
You must regularly check paint pipes and color changer and you must reduce residual
pressure before working on color valves and paint pipes.

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4 Transport and Storage
A T T E N T I O N
The following operations can be performed only by adequately trained personnel. See
chap. 3 of this manual
.
C A U T I O N
You must wear personal protective equipment
Always wear the
following equipment during assembly operations.
4.1 Transport
Normally the EcoDose 3K is shipped in a wooden crate. The wooden crate is made to be easily
transported on pallet trucks.
image indicative