Kremlin-Rexson PU 3000 User manual

INSTRUCTION MANUAL
ELECTRONIC MIXING MACHINE PU 3000
Manual : 1110 573.199.112
Date : 10/10/11 - Cancels : 14/12/10
Modif. : Update
TRANSLATION OF 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
150, avenue de Stalingrad
93 245 - STAINS CEDEX – France
Téléphone : 33 (0)1 49 40 25 25 Fax : [phone]
www.kremlin-rexson.com

KREMLIN REXSON Page 1 Manual : 573.199.112
TABLE OF CONTENTS
1. SAFETY INSTRUCTIONS ........................................................................................................................... 4
GENERAL SAFETY INSTRUCTIONS.........................................................................................4
SPECIFIC SAFETY INSTRUCTIONS .........................................................................................4
ENVIRONMENT...........................................................................................................................5
2. DESCRIPTION............................................................................................................................................. 6
3. OPERATING DESCRIPTION....................................................................................................................... 8
4. FEATURES .................................................................................................................................................. 8
5. INSTALLATION ........................................................................................................................................... 9
HANDLING...................................................................................................................................9
STORAGE....................................................................................................................................9
ENVIRONMENT ON THE AREA.................................................................................................9
DESCRIPTION OF THE LABEL MARKINGS............................................................................10
INSTALLATION DIAGRAM........................................................................................................11
INSTALLATION .........................................................................................................................12
CONNECTION OF THE CONTROL BOX AND OF THE FLUID FRAME.................................13
6. OPERATING .............................................................................................................................................. 13
DRIVING FROM THE MACHINE...............................................................................................13
SWITCHING ON THE MACHINE..............................................................................................13
7. FIRST SWITCHING ON............................................................................................................................. 15
8. FIRST PLACING INTO OPERATION........................................................................................................ 16
BEFORE SWITCHING ON........................................................................................................16
FLUSHING OF THE PUMPS AND OF THE MACHINE IN SOLVENT......................................16
START UP OF THE MACHINE .................................................................................................17
MIXING RATIO CHECKING......................................................................................................17
9. APPLICATION PROGRAMMING (F3) ...................................................................................................... 18
PASSWORD..............................................................................................................................18
PARAMETERS ..........................................................................................................................19
VALIDATION OF THE INITIALIZATION MODE........................................................................20
PRODUCTION (F1)...................................................................................................................21
FLUSHING (F2) .........................................................................................................................22
CONSUMPTIONS / PRINT (F4)................................................................................................22
10. INDICATIONS OF OPERATION GIVEN BY THE MACHINE.................................................................... 24
INDICATIONS GIVEN BY THE LEDS .......................................................................................24
MESSAGES GIVEN BY THE DISPLAY UNIT...........................................................................24
11. MAINTENANCE ......................................................................................................................................... 25

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SYNOPTIC.................................................................................................................................25
MAINTENANCE PLAN...............................................................................................................26
TROUBLESHOOTING...............................................................................................................27
DIAGNOSTICS ..........................................................................................................................27
12. PROPORTION AND OUTPUT ACCORDING TO THE RATIO................................................................. 28
13. MIXING RATIO........................................................................................................................................... 29
14. PNEUMATIC AND ELECTRIC DIAGRAMS.............................................................................................. 29
15. FEATURES - PU 3000 PNEUMATIC......................................................................................................... 31
COMPOSITION .........................................................................................................................31
TECHNICAL FEATURES ..........................................................................................................31
SPECIFIC PARAMETERS.........................................................................................................31
16. FEATURES - PU 3000 AIRMIX............................................................................................................... 32
COMPOSITION .........................................................................................................................32
TECHNICAL FEATURES ..........................................................................................................32
SPECIFIC PARAMETERS.........................................................................................................32
17. DISASSEMBLY & REASSEMBLY - PU 3000 PNEUMATIC, PU 3000 AIRMIX.................................... 33
MIXER........................................................................................................................................33
PILOTED VALVES.....................................................................................................................33
FLUID SECTION, MODEL 50 (BASE) (REFER TO DOC. 573.080.050)..................................34
FLUID SECTION, MODEL 50 F (CATALYST) (REFER TO DOC. 573.114.050)......................36
18. FEATURES - PU 3000 AIRLESS............................................................................................................... 39
COMPOSITION .........................................................................................................................39
TECHNICAL FEATURES ..........................................................................................................39
SPECIFIC PARAMETERS.........................................................................................................39
19. DISASSEMBLY & REASSEMBLY - PU 3000 AIRLESS .......................................................................... 40
MIXER........................................................................................................................................40
ASI 40 VALVES (REFER TO DOC. 573.062.050).....................................................................40
FLUID SECTION, MODEL ALTO 50CC (BASE) (REFER TO DOC. 573.395.050) ..................41

KREMLIN REXSON Page 3 Manual : 573.199.112
ADDITIONAL DOCUMENTATIONS :
Incorporation declaration and EC declaration of
conformity 578.013.130-UK
PU 3000 PNEUMATIC
PU 3000 Pneumatic Pump - Assembly Doc. 573.404.050
Pneumatic motor, model 1500 (only for PU3000) Doc. 578.009.110
BASE fluid section, model 50 Doc. 573.080.050
CATA fluid section, model 50F Doc. 573.114.050
Color changer and valve Doc. 573.187.050 + Doc. 573.188.050
LP fluid regulator (Spring operated) Doc. 573.215.110 + Doc. 573.415.050
HP fluid regulator, model 3/8 (260 bar / 3771 psi) Doc.573.299.050
PU 3000 AIRMIX 
PU 3000 Airmix Pump - Assembly Doc. 573.386.050
Pneumatic motor, model 3000 Doc. 573.387.050
BASE fluid section, model 50 Doc. 573.080.050
CATA fluid section, model 50F Doc. 573.114.050
Color changer and valve Doc. 573.187.050 + Doc. 573.188.050
Filter, model HP 3/8 (260 bar / 3770.8 psi) Doc.573.299.050
PU 3000 AIRLESS
PU 3000 Airless Pump - Assembly Doc. 573.389.050
Pneumatic motor, model 5000 Doc. 573.390.050
BASE & CATA fluid section, model 50cc Doc. 573.395.050
ASI40 valve Doc. 573.062.050
Filter, model HP 3/4 (360 bar / 5222 psi) Doc. 573.327.050
DIAGRAMS
Pneumatic and electric diagrams 055.680.031

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Dear Customer, You are the owner of our new PU 3000 mixing system and we would like to take this
opportunity to thank you.
Special care has been taken during all designing and manufacturing process to make sure your
investment will provide full satisfaction. Non-compliance with instructions and precautions stated in
this manual could reduce the equipment working life, resulting in operating problems and create
unsafe conditions.
1. SAFETY INSTRUCTIONS
GENERAL SAFETY INSTRUCTIONS
CAUTION : The equipment can be dangerous if you do not follow our
instructions concerning installation and servicing descri
bed in this
manual and in accordance with applicable European standards and local
national safety regulations.
Please carefully read all the instruction literature before operating your
equipment.
Only trained operators can use the equipment (To acquire an essential training, please contact the
"KREMLIN REXSON University" training center - Stains).
The foreman must ensure that the operator has understood the safety instructions for this equipment as
well as the instructions in the manuals for the different parts and accessories.
Read carefully all instruction manuals, label markings before operating the equipment.
Incorrect use may result in injury. This equipment is for professional use only. It must be used only for
what it has been designed for. Never modify the equipment. The parts and accessories supplied must be
regularly inspected. Defective or worn parts must be replaced.
Never exceed the equipment components' maximum working pressure.
Comply with regulations concerning safety, fire risks, electrical regulations in force in the country of final
destination of the material. Use only products or solvent compatible with the parts in contact with the
material (refer to data sheet of the material manufacturer).
Refer to 'Installation and safety instructions' document
(doc. 578.001.130)
SPECIFIC SAFETY INSTRUCTIONS
The control box of the PU 3000 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 § 7).
P
Do not install the paint drums underneath the pumps or the electric equipments. Place
them in front of the frame. Install a cover on the drums to reduce the diffusion of gas
and vapours in the booth.
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.
L
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 machine.

KREMLIN REXSON Page 5 Manual : 573.199.112
P
CAUTION : To prevent from any formation of gas and inflammable vapours,
use paint whose flash point is the highest possible (refer to materials' safety
instructions).
Before cleaning or removing components of the equipment, it is compulsory :
1 - to shut off the air supply,
2 - to open the gun fluid circuit and depressurize the hoses,
3 - to switch off the machine electrical supply.
ENVIRONMENT
This 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 2002/96/EC 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 in accordance with local rules and do not dispose of old equipment with household
wastes. A correct disposal of old equipment will help prevent negative consequences for the
environment and health.

KREMLIN REXSON Page 6 Manual : 573.199.112
B
2. DESCRIPTION
The PU 3000 proportioning system is designed for applying two component solvent or water-based paints
and lacquers.
There are three versions available :
- a pneumatic version (maximum pressure : 0-6 bar / 0-87 psi or 6-40 bar / 87-580 psi)
- an AIRMIXversion (maximum pressure : 180 bar / 2610 psi),
- an AIRLESS version (maximum pressure : 350 bar / 5076 psi),
It is under an independant form only supplied with compressed air (maximum 6 bar / 87 psi) and an
electric supply (115V / 230V).
It consists of :
- a control box with PLC and electromagnetic control components,
- a frame supporting a BASE pump, a CATALYST pump, the automatic valves for the materials and the
solvent, and electropneumatic control components.
A : Electronic control box with display unit
B : Air equipment
C : Mixing unit
HB : BASE fluid section
HC : CATALYST fluid section
MP : Pneumatic motor
30 : Mixer
Option : Flushing pump
Nota : drawing of a pump, model PU 3000 Airmix
A
MP MP
C
HB 30 HC

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FRONT VIEW OF THE CONTROL BOX
Ind. Description Fonction
13 Red LED Fault
14 Orange LED Working (other than production)
15 Green LED Production
The machine is totally programmable via a man/machine interface. The screen indicates continously, by a
simple identification, the status of the machine and it enables the operator to have access to the essential
functionalities : ON / OFF - FLUSHING / PRODUCTION.
The information relating to the operating of the machine (real time display of the ratio, of the
consumption…) can be read on the LCD screen.
The PU 3000 continously saves data on the consumptions of base, catalyst and solvent as well as the
total consumptions and the emissions of Volatile Organic Compounds (VOC) during the operation of the
machine.
On the box of the machine, a seal gland enables an electrical supply to the machine with electricity via a
safety isolating switch (115V / 230V).
The pictograms located under the screen allow the user to remember easily the various functions
managed by the PU 3000.
Pictogram Mode
Production
Flushing
Parameters
Consumptions / Print
Feeding of the pumps
14
15
13

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3. OPERATING DESCRIPTION
The 2 BASE and CATALYST materials are sent to the mixing machine from 2 pumps.
In production, as well as in regeneration, the machine injects a small volume of catalyst (P-6) in the base
continuous flow.
The PLC continuously checks the mixing ratio and if it notices a fault that it cannot correct, an alarm is
activated. The machine goes into safety mode.
The capacity of the pumps is configured (for the BASE pump : P4 parameter, for the CATA pump : P5
parameter) depending upon the equipment versions.
4. FEATURES
Number of colors : 1
Number of catalyst : 1
Solvent and water-based paints compatibility
Control via a magnet in the control box
Continuous mixing check
Adjustable threshold alarm
Adjustable pot-life indicator
Automatic flushing cycle (time)
VOC display
Consumptions' total indicator : base, cata, solvent,
VOC
Printing (connection to a printer)
Voltage : 230V / 115V - 10W
Air pressure: Mini 4 bar / 58 psi - Maxi 6 bar / 87 psi
Operating pressure :
from 0-6 bar / 0-87 psi or from 6-40 bar / 87-580 psi
for the pneumatic version
from 30 to 180 bar / from 436 to 2610 psi for the
Airmixversion
from 60 to 350 bar / from 870 to 5076 psi for the
Airless version
Adjustable mixing ratio : from 0.6/1 to 20/1 (BASE
volume / CATALYST volume) (from 160% to 5%)
Mixing precision : 1 %
Répeatability : 1 %
Mixed fluid output : refer to § 14 & 15
Maximum operating temperature : 50° C / 122° F
Weight : 115 kg / 253.5 lb (Pneumatic version)
187 kg / 412 lb (Airmixversion)
217 kg /478 lb (Airless version)
Dimensions :
- Control box : 355 mm x 275 mm x 135 mm
- Fluid frame : 855 mm x 670 mm x 1270 mm
(Airmixversion)
960 mm x 670 mm x 1400 mm (Airless version)
Connections :
Air inlet : F 3/4 BSP (air inlet valve)
Fluid outlet (mixer) :
F 3/4 JIC or assembly of a fitting (M 1/2 JIC)

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5. INSTALLATION
HANDLING
The PU 3000 system with relevant weight and dimensions
must be handled by appropriate means.
Nota : The handling of the machine must be carried out by a
qualified staff, in an appropriate space, correctly cleared to
avoid any risks of fall or of crushing of people.
Nota : The ring located above the cover is for the
hoisting of the pump and shall not be used for the
handling of the complete machine.
The frame has 4 holes (9) to be fixed on a bracket or on
the floor.
STORAGE
Storage before installation :
- Storage ambient temperature : 0 / + 50 °C. / 32 / +122° F
- Protect the equipment against dust, running water, dampness and shocks.
Storage after installation :
- Operating temperature : + 15 / + 35 °C. / + 52 / + 95° F
- Protect the equipment against dust, running water, dampness and shocks.
ENVIRONMENT ON THE AREA
The pump must be installed on a horizontal stable floor (eg : flagstone).
Ensure the machine is stable.
The working area must be correctly ventilated.