Romer PROTON II User manual

1
Manual coating equipment
PROTON II

Manufacturer of high quality equipment for powder coating
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Spis treści
General safety regulations.............................................................................................................................4
Safety symbols (pictograms)......................................................................................................................4
Static charges .........................................................................................................................................7
Grounding ..............................................................................................................................................7
PROTON II "V" ...............................................................................................................................................9
Scope of delivery........................................................................................................................................9
PROTON II.....................................................................................................................................................10
Operating modes .....................................................................................................................................11
Technical Data..............................................................................................................................................12
PROTON II Manual gun control unit ........................................................................................................12
Start-up and operation ................................................................................................................................13
PROTON II CONTROL PANEL ........................................................................................................................16
Initial start-up...............................................................................................................................................19
Daily start up............................................................................................................................................20
Remote control by PROTON II manual gun..............................................................................................24
Error diagnosis of the software....................................................................................................................25
Spare parts list PROTON II............................................................................................................................28
Ordering spare parts ................................................................................................................................28
PROTON II Manual gun control unit ............................................................................................................29
Manual gun control unit - outside rear wall ........................................................................................30
Manual gun control unit - outside rear wall ........................................................................................31
PROTON II manual powder gun ...................................................................................................................33
Scope of delivery......................................................................................................................................33
Technical Data..............................................................................................................................................34
PROTON II manual powder gun ...............................................................................................................34
Start-up and operation ................................................................................................................................35
Connecting guide .....................................................................................................................................35
Function check .........................................................................................................................................37
Start-up ....................................................................................................................................................38
Maintenance and cleaning...........................................................................................................................39
Daily maintenance ...................................................................................................................................39
Weekly maintenance ...............................................................................................................................39
Cleaning........................................................................................................................................................40
Troubleshooting guide .................................................................................................................................43
General information ................................................................................................................................43
Spare parts list PROTON II............................................................................................................................44
Ordering spare parts ................................................................................................................................44

Manufacturer of high quality equipment for powder coating
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PROTON II manual powder gun - spare parts list ........................................................................................45
PROTON II manual powder gun - spare parts list ........................................................................................46
PROTON II manual powder gun - spare parts list (cont.).............................................................................47
PROTON II manual powder gun - accessories..............................................................................................48
PROTON II flat jet nozzles - overview.......................................................................................................48
PROTON II round jet nozzles - overview ..................................................................................................49
Powder hose connectors - overview........................................................................................................50
Injector G2 ...................................................................................................................................................51
Principle of the injector and influence of ................................................................................................51
supplementary air...................................................................................................................................51
Powder volume setting table for G2 injector ..........................................................................................52
Guide values for PROTON /PROTON II with G2 injector......................................................................53
Cleaning and maintenance ..........................................................................................................................54
Injector cleaning.......................................................................................................................................54
Cleaning the check valves ........................................................................................................................55
Troubleshooting guide .................................................................................................................................56
Problem fixing ..........................................................................................................................................56
Spare parts list G2 ........................................................................................................................................57
Ordering spare parts ................................................................................................................................57
G2 powder injector (G2 type) - spare parts list ...........................................................................................58
G2 powder injector (G2 type) - spare parts.............................................................................................59

Manufacturer of high quality equipment for powder coating
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General safety regulations
Safety symbols (pictograms)
The following warnings with their meanings can be found in the Ge-ma
operating instructions. The general safety precautions must also be
followed as well as the regulations in the operating instructions.
DANGER!
Danger due to live electricity or moving parts Possible consequences:
Death or serious injury
ATTENTION!
Improper use of the equipment could damage the machine or cause it to
malfunction. Possible consequences: Minor injuries or damage to equip-
ment
NOTE!
Useful tips and other information

Manufacturer of high quality equipment for powder coating
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General
information
General
danger
The manual coating equipment is built to the latest specification and
conforms to the recognized technical safety regulations and it is de-
signed for the normal application of powder coating.
Any other use is considered as non-conform. The manufacturer is not re-
sponsible for any damage resulting from this - the risk for this is assumed
by the user alone! If the manual coating equipment is to be used for
other purposes or other substances outside of our guidelines, then
ROMER should be consulted.
Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of conformity of use.
The relevant accident prevention regulations, as well as other generally
recognized safety regulations, occupational health and structural regula-
tions are to be observed.
Furthermore, the country-specific safety regulations also must be
ob-served.
Further safety and operation notices will be found on the
accompanying CD or on the homepage http://romerpp.pl
The start-up is forbidden until it has been established that the manual co-
ating equipment has been set up and wired according to the EU guide-
lines for machinery.
Unauthorized modifications to the manual coating equipment exempts
the manufacturer from any liability from resulting damages or accidents.
The operator must ensure that all users do have the appropriate training
for powder spraying equipment and are aware of the possible sources of
danger.
Any operating method, which will negatively influence the technical safety
of the powder spraying equipment, is to be avoided.
For your own safety, only use accessories and attachments listed in
the operating instructions. The use of other parts can lead to risk of
injury. Only original ROMER spare parts should be used!
Repairs must only be carried out by specialists or by authorized ROMER
service centers. Unauthorized conversions and modifications can lead to
injuries and damage to the equipment, and the ROMER guarantee
would no longer be valid.
These general safety regulations must be read
and understood mandatory be-fore start-up!

Manufacturer of high quality equipment for powder coating
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Electrical
danger
Explosion hazard
Slip hazard
The connecting cables between the control unit and the spray gun must
be installed in such a way, that they cannot be damaged during the op-
eration. Please observe the local safety regulations!
The plug connections between the powder spraying equipment and the
mains should only be removed when the power supply is switched off.
All maintenance activities must take place when the powder spraying
equipment is switched off.
The powder coating equipment may be able to be switched on only if the
booth is in operation. If the booth stops, the powder coating device must
switch off too.
The control units for the spray guns must be installed and used in
zone 22. Spray guns are allowed in zone 21.
Only original ROMER spare parts will guarantee that the explosion
protection will be preserved. If damages occur by using spare parts
from other manufacturers, the warranty or compensation claim is void!
Conditions leading to dangerous levels of dust concentration in the pow-
der spraying booths or in the powder spraying areas must be avoided.
There must be sufficient technical ventilation available, to prevent a dust
concentration of more than 50% of the lower explosion limit (UEG = max.
permissible powder/air concentration). If the UEG is not known, then a
value of 10 g/m³ should be considered (see EN 50177).
All unauthorized conversions and modifications to the electrostatic spray-
ing equipment are forbidden for safety reasons.
No safety devices should be dismantled or put out of operation.
The operating and job instructions has to be written in an understandable
form and in the language of the persons employed, and has to be an-
nounced in a suitable place in the working area.
Powder lying on the floor around the powder spraying equipment is a po-
tentially dangerous source of slipping. Booths may be entered only in the
places suitable for it.

Manufacturer of high quality equipment for powder coating
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Observe the
grounding regulations
Fire and
smoke prohibition
The stay for
persons with
cardiac pacemakers
is forbidden
Static charges
Static charges can have the following consequences: Charges to people,
electric shocks, sparking. Charging of objects must be avoided by a pro-
per grounding.
Grounding
All electricity conducting parts found in the workplace of 5 meters around
each booth opening, and particularly the objects to be coated, have to
be grounded. The earthing resistance of each object must amount to
maxi-mally 1 MOhm. This resistance must be checked/tested regularly
when starting work.
The condition of the work piece attachments, as well as the hangers,
must guarantee that the work pieces remain grounded. The appropriate
measuring devices must be kept ready in the workplace, in order to
check the grounding.
The floor of the coating area must conduct electricity (normal concrete is
generally conductive).
The supplied grounding cable (green/yellow) must be connected to the
grounding screw of the electrostatic manual powder coating equipment.
The grounding cable must have a good metallic connection with the coat-
ing booth, the recovery unit and the conveyor chain, respectively with the
suspension arrangement of the objects.
Smoking and igniting fire are forbidden in the entire plant area! All spark-
generating works are forbidden!
As a general rule for all powder spraying installations, persons with pa-
cemakers should never enter high voltage areas or areas with electro-
magnetic fields. Persons with pacemakers should not enter areas with
powder spraying installations!

Manufacturer of high quality equipment for powder coating
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Photographing with flashlight can lead to unnecessary releases and/or
disconnections by safety devices.
Photographing with
flashlight is forbidden
Disconnect the plugs before the machines are opened for
maintenance or repair.
The plug connections between the powder spraying equipment and the
mains should only be removed when the power supply is switched off.
Disconnect from mains
before maintenance
works take place
As far as it is necessary, the operating firm must ensure that the
operat-ing personnel wear protective clothing (e.g. facemasks).
The operating personnel must wear electrically conductive footwear
(e.g. leather soles).
The operating personnel should hold the gun with bare hands. If gloves
are worn, these must also conduct electricity.
These general safety regulations must
be read and understood mandatory
be-fore start-up!

Manufacturer of high quality equipment for powder coating
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PROTON II "V"
Scope of delivery
1. The control unit
2. Manual Gun
3. Injector
4. Stand with holder
5. Suction pipe / fluidized bed
6. Vibrating table
7. Carton of paint
8. Swivel arm sleeve
9. The filter (not visible)
10. Gun holder
11. Handle on snake powder
12. Quick couplings
13. Shelf
14. Circle Rubber
15. Rotary wheel
max. 10 bar / 145 psi
min. 6 bar / 87 psi
100-240 VAC, 50-60 Hz

Manufacturer of high quality equipment for powder coating
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PROTON II
1. The control unit
2. Couplings
3. Injector
4. The paint
5. Stand with holder
6. The rotary wheel
7. Circle Plastic
8. Reducing air filter
9. Holder powder hose (not visible)
10 Gun
11. The fluidizing plate