TDK relyon plasma piezo brush PZ3-i User manual

BA-PZ3_i_ML / F0354901
EN Operating instructions for piezobrush® PZ3-i integration unit 3
DE Betriebsanleitung piezobrush® PZ3-i Integrationseinheit 36
www.relyon-plasma.com
All rights reserved

Operating instructions for:
piezobrush® PZ3-i integration unit
BA-PZ3_i_ML / F0354901

EN
4
BA-PZ3_i_ML / F0354901
Thank you for purchasing a relyon plasma GmbH branded product. To get the best from your device,
please read these instructions carefully.
Important!
Read these instructions carefully before assembling, installing and starting up the
device!
Always follow the safety instructions! Failure to follow the safety instructions may result in
accidents, serious injury and serious damage to the device.
Train your staff! The operator/user is responsible for ensuring that personnel have fully understood
the operation of the device and the safety requirements.
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All rights reserved.
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Unauthorised copying and distribution of this document and the utilisation and communication of its contents
are strictly prohibited unless expressly authorised. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or design.
Translation of the original
operating instructions

EN
BA-PZ3_i_ML / F0354901
5
1Safety.........................................................................................................................................6
1.1 Residual risks....................................................................................................................................6
1.2 Information and obligations for the operator.....................................................................................8
1.3 Impermissible operating conditions...................................................................................................8
1.4 Emissions..........................................................................................................................................8
2Description of the device .........................................................................................................9
2.1 Intended use .....................................................................................................................................9
2.2 Scope of delivery...............................................................................................................................9
2.3 Description of the device.................................................................................................................10
2.4 Assignment of connecting lines ......................................................................................................12
3Technical data.........................................................................................................................13
4Transport/Storage...................................................................................................................13
5Installation...............................................................................................................................14
5.1 Unpacking .......................................................................................................................................14
5.2 Installation requirements.................................................................................................................14
5.3 Positioning of the components........................................................................................................15
5.4 Installation of the components ........................................................................................................16
5.5 Connecting up the gas supply.........................................................................................................18
5.6 Connecting up a device with digital I/O communication .................................................................18
5.7 Setting the module carrier...............................................................................................................19
5.8 Installation of several devices.........................................................................................................21
6Special note on the operation of the plasma process..........................................................22
6.1 General description.........................................................................................................................22
6.2 Carrying out surface treatment .......................................................................................................23
6.3 Measures to take after the surface treatment .................................................................................23
7Operation.................................................................................................................................24
7.1 LED display on the driver housing ..................................................................................................24
7.2 Switching signals.............................................................................................................................24
7.3 Error acknowledgement..................................................................................................................25
7.4 Installing / removing the exchange module.....................................................................................25
7.5 Commissioning of a device with digital I/O communication............................................................27
7.6 Changeover in error mode..............................................................................................................28
7.7 Working with the ‘Standard’ exchange module...............................................................................29
7.8 Working with the ‘Nearfield’ exchange module ...............................................................................29
7.9 Working with different exchange modules ......................................................................................29
8Taking out of service..............................................................................................................30
9Maintenance............................................................................................................................30
9.1 Cleaning..........................................................................................................................................30
9.2 Replacing an exchange module......................................................................................................30
10 Troubleshooting .....................................................................................................................31
11 Environment............................................................................................................................32
11.1 Disposal ..........................................................................................................................................32
12 Conformity/Standards ............................................................................................................32
12.1 CE ...................................................................................................................................................32
12.2 FCC.................................................................................................................................................32
12.3 Product standards...........................................................................................................................33
13 Spare parts..............................................................................................................................33
14 Optional accessories..............................................................................................................33

EN
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BA-PZ3_i_ML / F0354901
1 Safety
The device was designed in accordance with the relevant international standards.
However, as with any technical product, hazards may arise if the system is not used
properly or is used for purposes other than its intended use.
In addition to the safety instructions in this document, you must also comply with general
safety standards.
Caution –Danger!
When working with the device, please note and observe the safety instructions and
requirements in these operating instructions because non-compliance may result in
serious or fatal injury.
1.1 Residual risks
This device has been manufactured in accordance with the current state of the art.
However, it is impossible to eliminate residual risks.
Always adhere to the following safety instructions:
Caution –Electrical voltage!
This device is in protection class III.
- Arrange to have the electrical wiring installed by a qualified person.
- Only use PELV power supply units or connect the device to a PELV circuit.
- Arrange for a qualified person to check for compliance with the requirements for
basic protection and fault protection defined in DIN VDE 0100-410.
Hazard from electrical voltage. If there is any visible damage to the wiring:
- do not start up the device;
- replace the damaged parts or have them repaired by a qualified person.
Hazard from sparks on the piezo element and on the substrate to be treated:
- do not reach into the plasma discharge area;
- electrically conductive substrates must be earthed or protected against contact;
- do not use combustible gases as process gases. This device is only approved for
operation with compressed air or nitrogen.
- flammable or thermally sensitive materials could catch fire or get damaged. Where
necessary, check the compatibility of plasma treatment in advance. All work on
combustible substrates must be supervised.
Tripping hazard!
Lay all connecting lines and gas lines in appropriate
cable ducts. Lay cables such that they do not present a tripping hazard.
Tripping hazard!
Lay all connecting lines and gas lines in appropriate
cable ducts. Lay cables such that they do not present a tripping hazard.

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Attention –Emissions!
Dangerous amounts of the reaction gas ozone (O3) and nitrogen oxides may be
produced during device operation.
- Ozone concentrations of more than 0.2 mg/m³ can occur.
- Note that compliance with national health and safety measures is mandatory when
operating the device.
- Only use the device in conjunction with a suitable extraction system.
- Do not let the device run without supervision.
- Never point the device at people while it is operating.
- To exclude any possibility of dangerous amounts of ozone and nitrogen oxides being
produced in the event of a failure of the extraction system, we recommend monitoring
the extraction power in the process and only releasing the plasma generation while
the extraction system is active.
- Due to the corrosive effect of ozone, we recommend positioning a suitable
extraction unit as close as possible to the nozzle outlet to prevent corrosion or
damage to other devices or surfaces through contact with ozone.
Caution –Hot surface!
The exchange modules can become hot due to operation. Do not touch them until they
have cooled down, and ensure when working with exchange modules that they do not
damage surfaces that are not sufficiently heat-resistant.
Depending on the process parameters, the plasma process may heat up the workpiece
being treated. If necessary, allow the workpiece to cool down before handling it.
Attention –Damage to device!
The plasma generator may be damaged if it is operated without gas flow. This would
interrupt the supply of cooling medium required in operation.
- Monitor the gas flow and deactivate the device immediately if the gas flow is too
low or is interrupted.
Never touch the piezo element on the front side of the device with sharp-edged objects.
This component may be damaged by improper handling.
Protect the plasma generator from falls or other hard impacts which may damage the
electronics or the piezo element.
Caution! Device for use in an industrial environment
Conducted as well as radiated interference can cause problems to occur with this device,
potentially impairing its electromagnetic compatibility in other environments.

EN
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BA-PZ3_i_ML / F0354901
1.2 Information and obligations for the operator
•The system may emit interference.
- The device has been tested in accordance with EMC legislation.
- The operator must verify and assure electromagnetic compatibility with other
electrical and electronic equipment in the immediate vicinity of the system.
•Ensure that:
- operating personnel have read and understood these operating instructions.
- anyone working near the device is made aware of the dangers and is provided with
the necessary protective equipment.
- repairs are only carried out by qualified persons.
•In particular, make operating personnel aware of the safety instructions in this
document.
•Always keep the device in fully functional condition.
•Any modifications made to the device will invalidate the operating licence and the
warranty. Exception: if such modifications are expressly authorised by the
manufacturer.
1.3 Impermissible operating conditions
The device must not be operated under the following conditions:
•in explosive (Ex) zones;
•in areas with a severe build-up of dust;
•where there is excessive ambient humidity (see chapter 3);
•when installed at altitudes of more than 6,000 feet (2,000 m) above sea level;
•where there are strong vibrations;
•outdoors.
1.4 Emissions
The plasma generator produces the following emissions:
•Ozone (O3)
•Oxides of nitrogen (NOx)
Process medium
Gas flow
Emission/Production
speed
Air (compressed air)
10 l/min
Ozone < 0.1 g/h
Air (compressed air)
10 l/min
NO2< 5 mg/h
Air (compressed air)
10 l/min
N2O < 1 mg/h
Note!
As a precautionary measure, we recommend using an extraction system with a flow
volume of approx. 10 times the total amount of gas flow through the device (or devices) in
the immediate vicinity of the plasma outlet.
To prevent any dangerous amounts of ozone and nitrogen oxides from being produced if
the extraction system malfunctions, we recommend monitoring the extraction power in the
process and only releasing the plasma generation while the extraction system is active.

EN
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2 Description of the device
2.1 Intended use
The device is an integration unit for generation of what is known as a ‘cold’ discharge,
hereafter referred to as ‘plasma’. It is intended to be mounted in stationary devices or in
positioning units and is used for pre-treating various material surfaces prior to process
steps such as adhering or printing. The cleaning effect of the plasma can also be utilised.
Only use the device for the intended purposes. Failure to do so may restrict product
liability.
2.2 Scope of delivery
piezobrush®PZ3-i integration unit (1000 7000 00)
The scope of delivery includes the following components:
•Plasma generator/integration unit
(consisting of a driver unit and a module carrier)
•Connecting line between driver unit and module carrier (length 0.3 m)
•Assembly screws (2 units M3x30; 1 unit M3x6)
•Operating instructions
Not included:
•Power unit / voltage supply
•DC connecting lines and communication
•Exchange module

EN
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BA-PZ3_i_ML / F0354901
2.3 Description of the device
The individual parts of the device are shown and named in the diagram below. These terms
are used at corresponding points in the operating instructions
No.
Component description
1
Module ‘Standard’ (shown here installed in the device; not included)
2
Piezo element (firmly installed in the exchange module)
3
Integration unit (module carrier)
4
Integration unit (driver unit)
5
Locking ring
6
CONFIG cover
7
‘Digital I/O’ interface
8
‘Module out’ interface
9
‘DC in’ interface
10
‘Module in’ interface
11
‘Gas in’ interface
12
LED status display (3 LED: Plasma / Warning / Error)
13
Adjustment screw for module carrier
14
Locating pins for module carrier
15
Functional earth connection (M3)
1
2
3
4
7
10
11
8
9
12
13
6
5
14
15