Kremlin-Rexson CYCLOMIX MICRO+ User manual

INSTRUCTION MANUAL
CYCLOMIXTM
MICRO, MICRO +
MICRO + PH
MIXING MACHINE
Manual : 1412 573.191.112
Date : 15/12/14 - Cancels : 25/06/13
Modif.: Update
TRANSLATION FROM THE ORIGINAL MANUAL
IMPORTANT : Before 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
l
150, avenue de Stalingrad
93 245 - STAINS CEDEX – France
 : 33 (0)1 49 40 25 25 Fax : [phone]
www.kremlin-rexson.com

KREMLIN REXSON Page 1 Manual : 573.191.112
INSTRUCTION MANUAL
CYCLOMIXTM MICRO, MICRO + & MICRO + PH
MIXING MACHINE
TABLE OF CONTENTS
1. GENERAL SAFETY INSTRUCTIONS ......................................................................................................... 3
INSTALLATION REQUIREMENTS ............................................................................................ 3
EQUIPMENT REQUIREMENTS................................................................................................. 3
MAINTENANCE REQUIREMENTS............................................................................................ 4
ENVIRONMENT.......................................................................................................................... 5
2. DESCRIPTION ............................................................................................................................................. 5
3. OPERATING PRINCIPLE ............................................................................................................................ 7
4. TECHNICAL FEATURES............................................................................................................................. 8
5. INSTALLATION ......................................................................................................................................... 10
DESCRIPTION OF THE LABEL MARKINGS........................................................................... 10
INSTALLATION DIAGRAM....................................................................................................... 11
IMPLANTATION ....................................................................................................................... 12
CONNECTION OF THE CONTROL BAY AND OF THE FLUID PART.................................... 14
6. OPERATING .............................................................................................................................................. 15
DRIVING FROM THE MACHINE.............................................................................................. 15
SWITCHING ON THE MACHINE ............................................................................................. 15
7. FIRST SWITCHING ON ............................................................................................................................. 16
8. FIRST PLACING INTO OPERATION......................................................................................................... 18
FLUSHING OF THE PUMPS AND OF THE MACHINE INTO SOLVENT................................ 18
START-UP OF THE MACHINE ................................................................................................ 18
9. APPLICATION PROGRAMMING (F3)....................................................................................................... 19
PASSWORD ............................................................................................................................. 19
PROCEDURE TO GET THE VERSION NUMBER OF THE ELECTRONIC CARD................. 19
PARAMETERS FOR MACHINE WITHOUT CATALYST FLUSHING ...................................... 20
PARAMETERS FOR MACHINE WITH CATALYST FLUSHING.............................................. 21
10. PRODUCTION (F1).................................................................................................................................... 23
PROPORTIONING TEST ......................................................................................................... 24
11. FLUSHING (F2).......................................................................................................................................... 24
12. CONSUMPTIONS / PRINT (F4) ................................................................................................................. 26
13. DOWNLOADING DATA FROM CYCLOMIX MICRO TO A COMPUTER.................................................. 27
14. INDICATIONS GIVEN BY THE LEDS........................................................................................................ 31
15. MAINTENANCE ......................................................................................................................................... 31
TROUBLESHOOTING.............................................................................................................. 33
DIAGNOSTICS ......................................................................................................................... 34
16. DISASSEMBLY - REASSEMBLY.............................................................................................................. 36
MIXER....................................................................................................................................... 36
FLOWMETER ........................................................................................................................... 36
PILOTED VALVES (FLUID VALVES AND TEST VALVES) ..................................................... 37

KREMLIN REXSON Page 2 Manual : 573.191.112
ADDITIONAL DOCUMENTATIONS :
Declaration EC declaration of conformity Doc. 578.034.130-UK
Annexes Pneumatic & electric diagrams
Mixing ratio chart
Doc. 573.191.120
Spare parts CyclomixTM micro Doc. 573.359.050
Color changer Doc. 573.186.112 + 573.187.050 + 573.188.050
CyclomixTM : Flowmeters and sensors
replacement
Doc. 573.705.070

KREMLIN REXSON Page 3 Manual : 573.191.112
Dear Customer, You are the owner of our new CYCLOMIXTM MICRO mixing machine and we would
like to take this opportunity to thank you.
To make sure your investment will provide full satisfaction, special care has been taken by KREMLIN
during all designing and manufacturing processes. To obtain the best result, safe and efficient
operation of your equipment, we advice you to read and make yourself familiar with this instruction
and service manual.
1. GENERAL SAFETY INSTRUCTIONS
The CYCLOMIXTM MICRO mixing machine shall be installed outside the explosive
area. It shall be installed in a safe area (non-explosive area according to the ATEX
directive - refer to § 6).
The display unit must be moved 1 m / 3.3 ft away from the fluid module and not be
installed above that one.
WARNING : Any misuse of the equipment or accessories can damage them, result in serious body
injury, fire or explosion hazard and reduce the equipment working life. Read carefully the safety
instructions hereafter.
The personnel involved in operating and servicing this equipment must be aware of all safety requirements
stated in this manual. The workshop supervisor must be certain that the personnel has perfectly
understood the safety instructions and complies with them.
Read all instruction manuals as well as the tags of the equipments before operating the equipment.
Read local safety instructions and comply with them.
INSTALLATION REQUIREMENTS
Ground the equipments.
Use the equipment only in a well-ventilated area to prevent from serious body injuries, fire and
explosion hazards. Do not smoke in the spray area.
Never stock paints and solvents in the spray area. Always close the pots and the tins.
Keep the spray area clean and free from debris (solvent, rags,…).
Read paint and solvent manufacturer's technical instructions.
Spraying of some materials may result in hazardous working conditions. To protect the operator,
respirator mask, hand cream and glasses are required (Refer to chapter "Safety equipment" of
KREMLIN selection guide).
EQUIPMENT REQUIREMENTS
The operating pressure of these equipments is particularly high. Consequently, some precautions must
be taken in order to prevent from accidents and from unsafe working conditions.
Never exceed the components maximum working pressure of the equipment.
HOSES
Do not use hoses with a maximum burst-proof pressure less than four times the maximum service
pressure of the pump (see data sheet).
Be certain hoses are not crimped, leaking and not unrolled.
Be certain hoses are in good conditions and showing no evidence of damage.
Use only air hose with static conductor to connect the pump with the spray gun.
All fittings must be tight and in good condition.
PUMP
Ground the equipment (use the connection on the pump).
Do not use any product or solvent incompatible with the pump components.
Use the appropriate solvent for the material being sprayed to increase the equipment working life.

KREMLIN REXSON Page 4 Manual : 573.191.112
GUN
Never wipe the end of the tip with the fingers.
Always depressurize air and fluid hoses before carrying out any servicing on the gun.
Never point the spray gun at anyone or at any part of the body.
CYCLOMIXTM MICRO
Do not install the machine in an explosive area. It shall be in a safe area (non explosive
area).
The display unit must be moved 1 m / 3.3 ft away from the fluid module and not be installed
above that one.
Connect the control box to the mains supply fitted with a ground.
The fluid module is fitted with a ground. Connect the ground cable to earth.
Do not use any product or solvent incompatible with the machine components.
Use the appropriate solvent for the material being sprayed to increase the equipment
working life.
Wear protective glasses to protect the operator from possible discharges during the
handling of the CYCLOMIX TM MICRO machine test valves.
Do not use electrostatic spraying for water-based paints with a resistivity lower than 5 M.
MAINTENANCE REQUIREMENTS
Guards (air motor cover, coupling shields, connectors,…) have been designed for
safe use of the equipment.
The manufacturer will not be held responsible for bodily injury or failure and / or
damage to property due to removal or partial removal of the guards.
Never modify these equipments.
Check them daily, keep them in a good condition and replace the worn parts only with KREMLIN
parts.
Before cleaning or removing components of the equipment, it is compulsory :
1 - to stop the air supply,
2 - to open the gun fluid circuit to depressurize the hoses,
3 - to shut off the machine electrical supply,
4 - to open the drain valves.

KREMLIN REXSON Page 5 Manual : 573.191.112
ENVIRONMENT
The equipment consists of a label 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 2012/19/UE European Directive covers all equipments with a crossed-out bin
pictogram. Please inform yourself about the collection systems for electric and
electronic equipments.
Please act according to local rules and do not throw the old equipments with
household wastes. A correct disposal of the old equipment will help prevent
negative consequences for the environment and health.
2. DESCRIPTION
The CYCLOMIXTM MICRO mixing machine is designed for applying two-component paints and varnishes
(water-based or solvanted).
It is available for 2 technologies of application : pneumatic spraying, AIRMIX spraying
(maximum pressure : 172 bar / 2500 psi).
It comes in an independent form. It is only supplied with compressed air (maximum 6 bar / 87 psi) and a
mains supply (115V / 230V).
It consists of :
- a control bay (2) with automaton and electromagnetic control components,
- a fluid module (1) that receives the volumetric meters, the automatic valves for materials and solvents
and electropneumatic control components.
Material
outlet
Material
inlet
1
8
7
6
2
3
10
5
11
4
9a
12
9b

KREMLIN REXSON Page 6 Manual : 573.191.112
Captions :
1 Fluid module 7 Electrovalves
2 Control bay 8 Air flow switch
3 Display unit 9 Color changer
9a : base CTM
9b : cata CTM
4 Volumeters 10 Protective housing
5 Automatic valve 11 Three-way valve
6 Mixer 12 Non-return valve
CABINET FRONT PART
Ind. Description Function
- Red LED Fault
- Orange LED Operating (except production)
- Green LED Production
The machine is totally programmable via a man/machine interface. The screen indicates continuously by a
simple identification, the statuses of the machine and enables to have access to the essential
functionalities: ON / OFF - FLUSHING -PRODUCTION
The informations relating to the operating of the machine (real-time display of the ratio, of the
consumption…) can be read on the LCD screen.
The CYCLOMIXTM MICRO saves continuously the instantaneous consumptions of base, catalyst and
solvent as well as the total consumptions and the emissions of Volatile Organic Compounds (VOC) during
the operating of the machine.
On the machine bay, there is a cord grip. It enables to supply electricity to the machine via a safety
isolating switch (115V / 230V).
Do not use electrostatic spraying for water-based paints or paints with a
resistivity lower than 5 M.

KREMLIN REXSON Page 7 Manual : 573.191.112
3. OPERATING PRINCIPLE
The 2 BASE and CATALYST materials are sent to the mixing machine from 2 pumps or pressure tanks.
The base crosses a piloted valve (A1) and a meter (CA), the catalyst is directly sent to the meter (CB). The
cycle begins with the opening of the BASE valve (A1). The 2 meters send their informations to the
computer that shuts off the catalyst valve (VP6) when the computerized mixing ratio is reached.
The mixing process is based on a base constant flow. The catalyst flow is injected low under high
frequency. The injection is made directly into the base flux at the mixer level.
The automaton checks continuously the mixing ratio and if it notices a fault that it cannot correct, an alarm
is activated. The machine goes on safety mode.
TA
vp6
A1 SA
CB
CA
AR2
AR1
IN
ASA
MEL A2 A3
AA
B1 SB
BSB
A1 Base piloted valve (A) IN Three way-valve to mixer
SA Base solvent piloted valve(SA) TA Sampling outlet for the base
A2 Base piloted valve (depending upon version) CA Base meter
A3 Base piloted valve (depending upon version) CB Cata meter
B Catalyst piloted valve (depending upon
version)
VP6 Injection piloted valve
SB Cata solvent piloted valve (depending upon
version)
MEL Mixer

KREMLIN REXSON Page 8 Manual : 573.191.112
4. TECHNICAL FEATURES
Number of colors : 1 or 3
Number of catalyst : 1
Solvent paints compatibility
Piloting via magnet on the control bay
Print kit (connection to a printer)
Voltage : 230V / 115V - 10W
Minimum air pressure : 4 bar / 58 psi
Fluid pressure: from 2 to 175 bar / from 29 to 2538 psi
Weight : 25 kg / 55 lb
Dimensions :
- control bay : 370 mm x 172.5 mm x 110 mm
/ 14.6" x 6.8" x 4.3"
-fluidmodule:370mm x460mmx110mm
/ 14.6" x 18.1" x 4.3"
Fluid circuits (base and cata) made of stainless steel for
the CyclomixTM Micro and Micro+.
CATALYST circuit made of 316 L stainless steel Circuit
for the CyclomixTM Micro+ PH.
Adjustable mixing ratio : 1/0 and from 0,6/1 to 20/1 (BASE
volume / CATALYST volume) (0% and from 166% to 5%)
Measure precision : 1 %
Mixed fluid flow : from 100 to 2000 cm3/mn
Solvent flow : 7000 cm3/mn
Fluid viscosity : from 30 to 5000 cps
Mixing permanent check
Adjustable threshold alarm
Adjustable pot-life indicator
Automatic mixing control cycle
Automatic flushing cycle (time)
VOC display
Total indicator for base, catalyst and solvent
consumption
OPTION :
*Auto-wash (gun support)
You cannot go to production with the auto-wash, no
connection to the machine.
* Connecting cable (5 m).
* Pickit 2 (Electronic programming kit) : the kit allows you
to update the program on the electronic cards.
Connections :
-Air :
Inlet : F 1/4 BSP / Outlet : F 1/4 BSP
- Material : :
Inlet : M 1/2 JIC / Outlet : M 1/2 JIC

KREMLIN REXSON Page 9 Manual : 573.191.112
NOTA : The version 2.82 is only compatible on electronic boards with version higher than V.2.32. Here after
an overview of major versions :
Kinf of
processor
- Electronic
card
Manufacturing
date first units
Soft
version
Presence of error 6 Soft compatibility
with 2.82 latest
version
PIC 18F4520 - 2.31 - -
PIC 18F4620
09 Y 1001 2.32 - Yes
10 Y 1133 2.6 Yes Yes
14 Y 1152 2.82 Yes
- Can be setup with P12
Yes
Different versions of the CYCLOMIXTM MICRO :
Configurations BASE CATALYST
CYCLOMIXTM MICRO 1 base + 1 solvent 1 cata
3 bases + 1 solvent 1 cata
CYCLOMIXTM MICRO + 1 base + 1 solvent 1 cata + 1 solvent
3 bases + 1 solvent 1 cata + 1 solvent
CYCLOMIXTM MICRO+ PH 1 base + 1 solvent 1 cata + 1 solvent
3 bases + 1 solvent 1 cata + 1 solvent
The control bay is the same for all the versions of the CYCLOMIXTM MICRO.
You can change the configuration displacing the shunt located on the µ card (J7 terminal)
- (refer to"Annexes" - electric diagram, folio 2).