Hedson IRT POWERCURE User manual

IRT POWERCURE
Infrared-drying arch for vehicles
GB Operation Manual
701006 rev 7 ©Hedson Technologies AB 2018

1. Introduction to PowerCure
(Original language)
Manufacturer:
HEDSON TECHNOLOGIES AB
Box 1530
SE-462 28 VÄNERSBORG, Sweden
Tel. [phone]
www.hedson.com
This product conforms with the following standards or other normative documents:
SS-EN 60204-1, EN 12100-1, EN12100-2
EN 61000-6-3, EN61000-6-2,
EN 1539, EN 13355,
SS-EN ISO 9001
SS-EN ISO 13857
under the terms of the following directives
Machinery Directive 2006/42/EC
Directive 2014/30/EU on Electromagnetic Compatibility
The product is intended for the installation in spray or combined spray and dry booths for passenger cars or similar
motor vehicles. These booths must be conform to the European product standard EN 12215 (spray booths) and EN
13355 (combined spray and drying booths).
The control system of the IRT PowerCure comprises the following functions:
• Inhibition of spraying during the drying process
• Securing ventilation of the booth during the drying process
• Ventilation of the booth before the drying process
• Surveillance of the parking position and doors
The integrated control system is not intended to cover all safety orientated controls of the combined spray and drying
booths. In particular, the control system cannot replace the ventilation monitoring in the spraying operation.
The device may be operated only with a fully functional original control system. This is the only way to ensure that the
dryer cannot be switched on together with the operation of a spray gun.
The system should not be used for transportation or lifting purposes.
TABLE OF CONTENTS
1. Introduction to PowerCure........................................2
2. Product description.................................................... 3
3. Safety instructions....................................................... 4
4. Control of the arch......................................................4
5. Start-up / Operation ...................................................6
6. Care and maintenance............................................... 7
7. Installation and transport...........................................9
8. Specifications ..............................................................9
9. Spare parts list.............................................................9
10. Electrical schedules ....................................................9
11. Certificate of conformity ..........................................10
ANNEX I, Acceptance test ................................................11
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2. Product description
The IRT PowerCure generates infrared radiation, which
heats the coating directly on a vehicle. The arch is motor-
ized and automatically moves along the wall rails in the
booth. By means of movable side panels, all exterior
surfaces on a vehicle can be cured.
The curing process can be adjusted individually to the
vehicle’s dimensions and the properties of the used
paint. The settings can be saved and recalled via the
easy-to-use control system again.
The possibility for programmed radiation exposure of
only the necessary surfaces of the vehicle leads to time
and energy savings. Thereby, it helps you to run your
workshop cost-effective and environmental friendly.
TECHNICAL DATA
Rated voltage 400V~3Ph/PE ±5%
Nominal frequency 50 Hz
Nominal power 60 kW
Weight Arch 285 kg
Weight Rails 7 kg/m
Sound Pressure Level ≤ 70 dB(A) at 1 m
Sound power level ≤ 70 dB(A) at 1 m
Curing temp. (curing surface) Max. 170°C
Ambient temp. (in parked position) Max. 70°C
Ambient temp. (during operation) Max. 40°C
2.1 Layout
Mounting dimensions and vehicle dimensions: see picture
below (700908, 700909), all measurements are in mm.
*Top side rail
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3.1.5 Disposal
Dispose of used items at the nearest environmental
facility for recycling.
3.2 System safety
Emergency stop next to the operator panel.
3.3 Safety features
Safety switches on all entry doors terminates the process
when triggered. Interlocking with exhaust air pressure
switch. Double spray valve, monitored by pressure
switch. Double main contactors and safety relay. If these
protection measures are inactivated or if persons are
in the spray booth during operation of the PowerCure,
there are risks of clamping/crushing injuries and burns.
4. Control of the arch
4.1 Operation panel
Switch on the arch via the man switch. The arch is con-
trolled from the control panel which is designed too help
you operate the curing process in a simple and conveni-
ent way. The panel has a main menu with four different
options and various
settings (see below).
These are:
Automatic: Preprogrammed programs, see 5.1.1.
Manual: Make your settings manually, see 5.1.7.
Help: Search for help, see 5.1.10.
Setup: Setting tools for the panel, see 5.1.11.
4.1.1 Automatic
The automatic curing option allows you to easily select
the desired curing program, and you can then use the
same settings on several occasions.
4.1.2 Selection of surface to be cured
Select the drying surface of the vehicle by pressing the
respective point. A red mark appears at the selected
area.
You can cancel your selection by repressing.
4.1.3 Operation mode and choice of booth
Under the option “Booth”, you can choose which booth
to use for curing. If the workshop only has one booth, the
system will display the options “IRT sun” or “spray gun”.
This is to ensure that you can alternate between curing
and painting.
If the dryer is intended for two booths, you can chose
between the operation modes curing and painting after
you have chosen the booth.
2.2 Training instructions for operators
Instructions to the owner: in order to meet safety
requirements, the owner of the paint curing system must
ensure the instructions on arch usage and function are
available to those working with the arch. The instructions
must be understandable and written in a language that
the user understands. These instructions should also
be accessible at the work site in a place that is publicly
known.
3. Safety instructions
3.1 General
The facility works with 400 V 3 ~ / PE 50 Hz, which consti-
tutes a lethal voltage! Contact and changes to the electri-
cal equipment must only be performed by electrically
qualified persons.
The booth must have technical ventilation (booth aspira-
tion) with an air velocity of at least 0.15 m/s - also during
the drying process. The air volume flow has to be suf-
ficient in order to avoid solvent concentrations above 25
% of the lower explosion limit (LEL).
Intensive heat radiation; the paint curing arch must not
be used to warm up parts of the body (such as the hands
or face) and neither for warming up paint in cans or other
containers.
Temperature-sensitive plastic parts must be adequately
protected before the curing process starts.
Crushing hazard; Stay outside the booth during move-
ment of the arch. Before starting the process the opera-
tor must make sure that there is no other person in the
booth. As the arch does not have any proximity sensors,
ensure that there are no items within the traversing range
and that, during drying, the arch does not collide with
the vehicle. For example, markings on the floor could
facilitate the correct positioning of the vehicle.
Risk of slipping, tripping or falling; It is the responsibility
of the owner to identify the risk of slipping, tripping and
falling.
3.1.1 Stop in emergency situation
Equipped with emergency stop at the location of the
operator panel. This will disconnect the power to the
arch and spray valve.
3.1.2 Breakdown - to release a person caught in the
equipment
If a person is caught in the equipment push the
emergency stop and push the equipment by hand to
release the person.
3.1.3 Operation
No person may be in the spray booth when the
PowerCure is in use. The operator must make sure the
area is cleared before starting the machine. Before
first start up, after installation and service, carry out the
acceptance test in accordance with Annex I.
3.1.4 Cleaning
Cleaning of the sensor may be performed with a damp
cloth. Do not use running water or flammable liquids.
4701006 rev 7
GB

Communication
with arch
5.1.5.
Parking status
Car direction
Spray air mode
Parking garage
status
Power to
arch status
Spray booth
status
5.1.4.
Spray booth
mode
Doors status
SINGLE BOOTH
4.1.4 Selection of coating materials and colour group
Select the type of paint in the menu on the right side
panel and select the paint’s more specific colour in the
dropdown menu.
4.1.5 Car size
Select the approximate size of the car to be cured in the
sizemenu on the panel’s left side.
Drying surfaces
DOUBLE BOOTH
4.1.6 Saved settings
All your settings (except for colour selection) will be
saved, so they are automatically selected when you are
finished and want to start a new process.
Move the arch
Angle both arch sides
Curing distance
Choice of lamps
4.1.7 Manual
When you select Manual in the main menu on the left
you will see options to turn and move the arch manually.
After you’ve done your manual selection, complete the
process in the same order as in Section 5.1.4. by select-
ing the function, curing surface and paint materials.
Curing distance; The curing distance is counted from the
start position where the arch has been placed. When you
press the curing distance, a number pad pops up where
you can choose the travel distance of the arch.
Note! When you choose to use this feature, the turn
functionwill be disabled.
Turning and moving; In order to move the arch inside
the booth, use the top arrows on the panel. The arch
symbol indicates how far from the parking area you have
moved the arch. To turn the arch sides, use the rotation
arrows on the panel. Every time you make a change, the
angle is indicated on the screen.
To return the arch to the parked position, press the “Park”
button in the lower left corner on the panel.
Please be careful to avoid collision with the vehicle or oth-
er items in the booth, especially during manual turning.
Start the curing process by pressing START.
Warning! Make sure that no one is inside the booth, and
that no combustible material is lying on the floor.
4.1.8 Lamp selection
Use the panel picture of the arch to select which lamps
you want to use during the curing process. By pressing
the “A” button, you can quickly select all lamps.
4.1.9 Saved settings
All your manual settings (except for colour selection) will
be saved, so they turn up automatically when you are
finished and want to start a new process.
4.1.10 Help
When you select Help from the main menu on the left,
you will find this manual in an electronic format.
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4.1.11 Setup
Setup on the main menu contains various settings to
facilitate the use of the panel;
- Show cursor
- View arch status (during curing)
- Automatic lamp test
The configuration options for “Drying recipes” and “Car
size” are only available using a PIN code for the ad-
vanced user.
4.1.12 Logs
Statistics
Statistics of cured sessions. Start, RunTime, Used energy,
Time, colour selection, part selection.
Log Messages
List of error messages.
5. Start-up / Operation
5.1 Before start (Automatic mode)
Please note! Starting is only possible when the arch is in
the parked position. Make sure that no one is inside the
spray booth before start.
5.2 Start-up
Starting the arch; Carefully check that all settings are prop-
erly selected before pressing the START button to begin
the curing process. The drying process will start time-de-
layed only if the air in the booth has been changed by the
forced ventilation (this takes about 180 seconds)
6701006 rev 7
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NOTE: If you have more than one spray booth, you must
specify which booth you want to use. Make this selection
in the upper left corner of the panel.
Warning! Make sure that no one is inside the booth, and
that no combustible material is lying on the floor.
5.3 Operation
Arch position; The symbol P in the upper left corner
indicates that the arch is in its parked position. While
curing or when the arch is moving, a progress indicator is
displayed and the parking symbol is crossed out.
The contact icon in the upper left corner indicates the
status of the communication between the arch and
equipment outside the booth.
5.4 Stop
Stopping the arch; To stop or pause the curing process,
press STOP in the lower right corner of the panel. When
this feature is used, a new menu box is displayed. Press
Continue to continue the curing process, or Park to stop
it altogether. If you press park, the paint curing arch will
return to its parking position.
5.5 Resetting after emergency stop
Twist the emergency button and reset the alarm on the
operations panel.
5.6 Operational data
Machine status; The status of the machine is indicated by
the symbols in the upper right corner of as follows:
- Curing / Spraying
- The roller door between the booth and the parking
space is open/in motion/closed
- The entry door to the booth is open/closed
- Power to the booth is on/off
- Ventilation for the booth is on (fan symbol rotates)/
off (fan symbol does not rotate)
5.7 Operation interference
See illustrations on page 4-5.
6. Care and maintenance
6.1 General
NOTE! All maintenance and repairs should only be
performed by trained and qualified personnel and only
when the machine is in a non-energized state. Switch
off power supply and lock the main switch. Break the
air supply and vent out the pressurized air. Use a four-
legged ladder / platform at the service of the parts
situated in the roof part of the arch. It is the responsibility
of the user to ensure this. Maintenance work is only to be
carried out at the stipulated intervals by suitably trained
personnel. Do not use running water or flammable
liquids. Abide by the following points to ensure a long
service life and continous operation of the PowerCure:
- Only original spare parts may be used
- Adhere to the maintenance intervals
- Contact the manufacturer´s customer service
department regarding any maintenance work that
is not listed or shown in this or the extended service
manual (701035).
6.2 Trouble Shooting
Drying does not start
- Check alarms
- Roller door in wrong position (down) (closed) (indi-
cated on the panel)
- No power supply, turn on the main switch and check
the fuses.
- Check the fuses in the monitoring cabinet and arch.
Note! This may only be performed by qualified per-
sonnel.
- Entrance doors to spray booth are not closed.
Ventilation time still counting.
No compressed air in the booth before/after drying;
- Check alarms
- Select “Spraying” as described in the 5.1.3 Operation
mode and choice of booth”.
- The arch is not in the parked position. (Indicated on
the control panel)
- Roller door at the parking position is not completely
closed. (Indicated on the control panel)
- Check the voltage supply. (Indicated on the control
panel)
6.3 Maintenance schedule
Monthly or after 400 curing, whichever comes first
- Check that the gold foil of the reflectors is not
damaged or heavily soiled and that all light lit up
during operation. Damaged or soiled foils should be
replaced to maintain proper heat distribution.
- Check that the PowerCure Arch is moving smoothly,
tension the spring at the driving wheel if necessary.
Quarterly or after 800 curing, whichever comes first
- Check that the gold foil of the reflectors is not
damaged or heavily soiled and that all light lit up
during operation. Damaged or soiled foils are
replaced to maintain proper heat distribution.
- Check that the PowerCure Arch is moving smoothly,
tension the spring at the driving wheel if necessary.
Yearly or after 2500 curing, whichever comes first
- Check that the gold foil of the reflectors is not
damaged or heavily soiled and that all light lit up
during operation. Damaged or soiled foils are
replaced to maintain proper heat distribution.
- Replace the driving wheels on both sides and Control
the travel of the arch. Part number for order: 713967.
Loosen the tension spring at the driving wheel on
both sides and check that the arch is still is traveling
smoothly before tensioning the travel wheel again.
The force needed to push the arch by hand should
not exceed 200N (20kg).
- Check that the PowerCure arch park perpendicular
(90 degrees angled) to the rails. If not adjust the
parking sensor position until it park completely
perpendicular to the rails. Control also that the
sensors work properly and are well fixed and clean.
- Check the roller port sensors work properly and are
well fixed and clean
- Check the ventilation sensor work properly and are
well fixed and clean.
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701006 rev 7 GB

Tools for Service and maintenance
The following tools are needed for the installation:
TOOL SIZE QTY
Socket wrench kit metric 1
Box-end wrench 10 mm 1
Box-end wrench 13 mm 2
Box-end wrench 18 mm 2
Screwdriver Philips 2 1
Screwdriver flat 2, 3, 4, 6 mm 1 ea
Allen key 4, 5, 8 mm 1 ea
Pointed pliers 1
Cutting pliers 1
Multimeter 1
Measuring tape (Booth width) 1
Level instrument (laser) (Booth length) 1
Ladder, fourlegged Suitable for working
height 2,5 m
1
Forklift >350 kg 1
Protection gloves 2 pairs
Replacing the IRT lamps
WARNING! Before any intervention in the system, the
voltage must be disconnected. Do not remove the pro-
tective cover of the lamp until the IRT lamp is mounted.
1. The protective grille is attached at both ends with
screws. Loosen them until the fastening plates be-
come loose (see Figure 7.1).
Figure 7.1.
2. Push the protective grille to the side and remove it.
3. The lamps are secured by a screw at each end. Loosen
them so far as to free the lamp ends (see Figure 7.2)
Figure 7.2
4. Pry up the lamp holder using a screwdriver. The lamp
can now be removed and replaced (see Figure 7.1.3).
Figure 7.3
IMPORTANT! Never touch the glass or reflectors with
your hands.
5. Install the new lamp in the upper bracket. Make sure
the holder goes in as far as possible under the square
washer.
6. Tighten the screw. Bend the bracket at the lower end
of the lamp by hand and attach it the same way as the
upper one.
7. Center the IRT lamp in the reflector body both longi-
tudinally and laterally.
8. Remove the protective cover from the IRT lamp.
9. Refit the protective grille.
Tightening the drive wheel
If the drive after a while begins to slip:
1. Check that the wheel and the aluminum rail are clean.
2. Make sure the rails are still properly aligned.
3. Increase the wheel pressure against the rail.
Tension the spring using an 18 mm key until the drive
wheel is not slipping.
(For extended service, see «IRT PowerCure» art nr 701035)
8701006 rev 7
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7. Installation and transport
7.1 Installation
The control panel must be located outside the booth in
a place with full visibility into the booth (e.g. close to an
inspection window). In case that the arch is intended for
the use in two booths, both booths must be completely
visible (e.g. by mounting on a swinging arm). In such
a case the booths must be clearly and good visibly
assigned to the respective selection possibility in the
control panel (“1” or “2”)
Note: The parked paint curing arch must not limit any
escape route!
The booth must have the needed spatial capacities for
parking the arch in a position protected from spray-
ing fog. This might be for example a port between two
subsequent booths. Otherwise the lifetime of both the
IR-lamps and the arch in general will be significantly
reduced.
Electric installation
The electrical installation must be performed by an
electrically qualified installer or by someone under his
supervision and monitoring.
Before you start the installation, read necessarily the
assembly instruction manual (document 701001) and fol-
low all described advices and specifications.
NOTE: The installation must comply with applicable
regulations.
Check items prior to start up
1. Installation verification of the mechanical part by the
responsible installer (Annex I, Mechanical Part).
2. Inspection of the power supply and electric
installation (Annex I, Electric part).
3. Prepare a log of the results from initial
commissioning and submit one copy to both the
workshop management and the system supplier.
7.2 Transport
Transport of crates to site of installation with the help of
fork lift.
8. Specifications
8.1 Technical information
See chapter 3. Product description.
8.2 Noise and vibration
See chapter 3 Product description.
9. Spare parts list
9.1 Spare parts list
MECHANICAL SPARE PARTS
Part No Description Req. No.
In Stock
Drawing
(see 701035
Extended
service and
maintenance
manual
713967 Driving Wheel Ø 57 mm 2 713599
800196 Reflector Complete 1 713590/
713700
710695 Protection Net 2 713599
ELECTRICAL
102701 IRT-Lamp 790 3 kW 2 713590/
713700
180521 Limit Switch IRT-7000 2 713599
713547 Transport Motor Unit 1 713599
750409 Op PowerCure 1
193092 Distance Sensor Laser Ifm 1 713700
129027 Fan 1 713700/
713590
122437 Sensor Ind 1 713700
750300 Transformer 230/400/480
V ac/12 V dc
1 713700
195386 Contactor 80 A, 230 V 1 750410
180520 Voltage Suply Unit 1 750410
129014 Plc Ethernet Bc 9100 1 750410
129015 I/O D-In 8 Ch 1 750410
129024 I/O D-In 4 Ch 1 750410
129026 I/O Power Measure 1 750410
195392 Relay 2- Pol 24 V 1 750410
129022 I/O D-Out 8 Ch 1 750410
713534 Turning Drive Unit 1 713534
193942 Solid State Relay 1 750410
For other electrical parts see Electrical Diagram
EXPANDABLE PARTS
713967 Driving Wheel Ø 57 mm 2
102701 IRT-Lamp 790 3 kW 2
713248 Protection Foil Operation-
panel
2
10. Electrical drawing
See 750410 - PowerCure.
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701006 rev 7 GB

11. Certificate of conformity
We,
HEDSON TECHNOLOGIES AB
Hammarvägen 4
SE-232 37 ARLÖV
Sweden
declare under our sole responsibility that the product:
IRT PowerCure that this declaration relates to conform
with the following standards or other normative docu-
ments:
SS-EN 60204-1, EN 12100-1, EN12100-2
EN 61000-6-3, EN61000-6-2,
EN 1539, EN 13355,
SS-EN ISO 9001
SS - EN ISO 13857
under the terms of the following directives Machinery
Directive 2006/42/EC Directive 2014/30/EU on Electro-
magnetic Compatibility
Arlöv, Sweden March 3rd, 2016
CEO
10 701006 rev 7
GB

ANNEX I, Acceptance test
Acceptance test carried out by the responsible assembler / electrician prior to commissioning.
Ref. Software version
System
Issued by Date
Type Copy for the system
supplier
Mechanical part
MONITORING DEVICE AND OPERATOR STATION
Located outside and near the booth.
The inside of the booth is visible from the
control panel.
RAILS
Same height (horizontal ± 2 mm) *
Steady and securely fastened.
Satisfactory strength.
Contact rails well protected by labyrinth
seal.
The arc moves freely throughout the area.
WARNING SIGNS
Signs «Unauthorized persons may not
enter» mounted on all entry doors.
PARKING POSITION
Parking position sensor is functioning and
properly installed.
Parking arch is steadily and firmly secured
The arch is easy to drive in.
The arch is well protected in the parked
position.
Temperature switch mounted
NEGATIVE PRESSURE SWITCH IN EXHAUST AIR
DUCT
Adjusted for proper operation.
Max 2 m hose length.
No formation of water pockets in the hose.
SAFETY
Emergency stop installed at operator´s
panel.
Entry door switches mounted on all entry
doors.
*) Floors often incline more than 2 mm Use a spirit level (preferably with a laser)
Electrical part
VISUAL INSPECTION
Power supply properly fused.
The main cable to the monitoring unit
4 x .....mm².
Protected main terminals.
Sealed lead-ins.
PE and other terminals securely connected.
Correctly connected bus bar (PE!).
Conductor rail IP 4 x.
Correctly connected arch (PE!).
Correctly connected operator panel (PE!).
Measurements according to EN 60204-1 /
VDE 0113-1, Chapter 18.
Carrying out with measuring instrument
(manufacturer, Type, Series-No.):
• ………………………..…….... Value: ………..…
• ………………………..…....… Value: ………...…
• ………………………........….. Value: ………....…
FUNKTION TEST WITH POWER
Main switch on.
Exhaust air on.
Solenoid valve on (spray air on) with the
arch in the parked position and spraying
selected.
Solenoid valve off (spray air off) when IR
curing is selected
Fans of the arch start when lamps light up.
Position switch in the parking position
securely fastened.
All lamps can be switched on
The arch’s two sides can be rotated in both
directions
The arch can run over the full surface,
without jerking or the drive wheel slipping
at high / low speed
Emergency stop
Entry doors switches
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701006 rev 7 GB

HEDSON TECHNOLOGIES AB
Hammarvägen 4, 232 37 Arlöv
Tel [phone]
Telefax [phone]
www.hedson.com
HEDSON TECHNOLOGIES AB
Box 1530, SE-462 28 Vänersborg
Tel [phone]
Telefax [phone]
www.hedson.com
© Hedson Technologies 2018
The manufacturer reserves the right to introduce technical modifications.