TDK relyon plasma piezo brush PZ3-i User manual

Operating instructions for:
piezobrush® PZ3-i integration unit
BETA-TEST
BA-PZ3_i_ML / F0354900

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beta-test / preliminary
EN
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.
© Copyright relyon plasma GmbH 2021.
All rights reserved.
Text, images and diagrams and their layout are protected by copyright and other laws. Unauthorized
copying and distribution of this document and the utilization and communication of its contents are strictly
prohibited unless expressly authorized. Offenders will be held liable for the payment of damages. All rights
reserved in the event of a patent, utility model or ornamental design registration are granted.

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EN
1Safety.........................................................................................................................................4
1.1 Residual risks....................................................................................................................................4
1.2 Information and obligations for the operator.....................................................................................6
1.3 Impermissible operating conditions...................................................................................................6
1.4 Emissions..........................................................................................................................................6
2Description of device................................................................................................................7
2.1 Intended use .....................................................................................................................................7
2.2 Scope of delivery...............................................................................................................................7
2.3 Description of device.........................................................................................................................8
2.4 Connecting lead assignment.............................................................................................................9
3Technical data.........................................................................................................................11
4Transport / storage .................................................................................................................11
5Installation...............................................................................................................................12
5.1 Unpacking .......................................................................................................................................12
5.2 Installation requirements.................................................................................................................12
5.3 Positioning the components............................................................................................................12
5.4 Mounting the components...............................................................................................................14
5.5 Connecting the gas supply..............................................................................................................15
5.6 Connecting the connection cable Digital I/O...................................................................................15
5.7 Adjusting the module carrier ...........................................................................................................16
6Special note on the operation of the plasma process..........................................................18
6.1 General description.........................................................................................................................18
6.2 Carrying out surface treatment .......................................................................................................19
6.3 Measures to take after the surface treatment.................................................................................19
7Operation.................................................................................................................................20
7.1 LED indicator on driver unit.............................................................................................................20
7.2 Switching signals.............................................................................................................................20
7.3 Error acknowledgement..................................................................................................................20
7.4 Inserting / removing the module......................................................................................................21
7.5 Commissioning a device with digital I/O communication................................................................22
7.6 Working with module “Standard”.....................................................................................................23
7.7 Working with module “Nearfield”.....................................................................................................23
7.8 Working with other modules............................................................................................................23
8Taking out of service ..............................................................................................................24
9Maintenance............................................................................................................................24
9.1 Cleaning..........................................................................................................................................24
9.2 Replacing a module ........................................................................................................................24
10 Troubleshooting .....................................................................................................................25
11 Environment............................................................................................................................26
11.1 Disposal ..........................................................................................................................................26
12 Conformity / standards...........................................................................................................26
12.1 CE ...................................................................................................................................................26
12.2 FCC.................................................................................................................................................26
12.3 Product standards...........................................................................................................................27
13 Spare parts..............................................................................................................................27

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1Safety
This device is built according to corresponding international standards. Like with every
technical product incorrect or not intended use can however be dangerous.
Follow the instructions in this operating manual in addition to the general safety regulations.
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!
The IEC protection class of this device is class III.
- Only electricians may connect the electrical wiring
- Only use SELV/PELV power supplies
- Let a qualified person check, if the requirements of the basic protection and the
error protection according DIN VDE 0100-410 are fulfilled.
Danger from electrical voltage. If the wiring is visibly damaged:
- Do not use the damaged part.
- Have the damaged parts repaired by a qualified person or replace them.
Danger from sparks on the piezo element and the substrate to be treated:
- Do not reach into the area of the plasma discharge.
- Electrically conductive substrates must be grounded or protected against touching.
- Use air or nitrogen as working gases only! Do not use flammable working gases!
- Flammable or thermal sensitive materials could be ignited or damaged. Check the
compatibility of the plasma treatment before. Never treat flammable materials
unattended.
Trip hazard!
Lay the connection cables and gas pipes in suitable cable trays. Lay cables such that they
do not present a trip hazard.

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Attention –Emissions!
Dangerous amounts of the reaction gas ozone (O3) may be produced during device
operation.
- Volumes of ozone in excess of 0.2 mg/m³ may be produced.
- Note that national health and safety measures must be observed when operating
the device.
- Only use the device in well ventilated areas or in conjunction with a suitable
extraction device.
- Do not leave the device running unattended.
- Do not point the device at people when in operation.
- In order to rule out the possibility of dangerous amounts of ozone being produced in
the event of a failure of the extraction system, we recommend monitoring the
extraction power in the process and only enabling plasma generation when the
extraction system is active.
- Due to the corrosive effect of ozone we recommend to place a suitable gas
extraction as close to the nozzle outlet as possible to avoid corrosion/damage of
other devices/surfaces.
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 stop the device immediately if insufficient gas flow is
detected.
Never touch the piezo element at the front of the device with sharp-edged objects. This
component may be damaged by improper handling.
Protect the device from falls or other hard impacts which may damage the electronics or
piezo element.
Caution –hot surface!
The exchange modules can become hot during operation. Do not touch them until they
have cooled down and take care not to damage thermally sensitive surfaces when working
with the exchange modules.
The workpiece to be treated can also heat up during the plasma process, depending on the
process parameters. If necessary, allow the workpiece to cool down before touching it.
Attention! Device for use in industrial environment
Due to the presence of both conducted and radiated interference, this device may have
difficulty in ensuring electromagnetic compatibility in other environments.

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1.2 Information and obligations for the operator
•The system may emit interference.
- The system will be 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 system in fully functional condition.
•Any modifications made to the device will invalidate the operating license and the
warranty. Exception: Such modifications are expressly authorized 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 severe build-up of dust
•In environments where the humidity is too high (see chapter 3)
•At altitudes of more than 2.000 m above sea level
•Where there are strong vibrations
1.4 Emissions
The connected device produces the following emissions:
•Ozone (O3)
•Nitrous gases (NOx)
Process gas
Gas flow
Emission/production rate
Air (CDA)
10 l/min
Ozone < 0,1 g/h
Air (CDA)
10 l/min
NO2 < 5 mg/h
Air (CDA)
10 l/min
N2O< 1 mg/h
Note!
As a precautionary measure, we recommend an extraction system with about 10-times
the flow rate of the entire gas flow through the device (or the devices) in the direct vicinity
of the plasma outlet.
To avoid the possibility of dangerous amounts of ozone 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 when the extraction system is active.

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2Description of device
2.1 Intended use
The piezobrush® PZ3-i is an integration unit for generating technical plasma. It is
intended to be mounted in stationary machines or in positioning units and is used for
pre-treating various material surfaces prior to process steps such as adhesive
bonding or printing. The cleaning effect of the plasma can also be utilized.
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 driver unit and module carrier)
•Connection cable between driver unit and module carrier (length 0,3 m)
•Connection cable DC (length 10 m)
•Connection cable communication (length 10 m)
•Module “Standard”
•Module “Nearfield”
•Mounting screws (2 pcs M3x30; 1 pc M3x6)
•Operating instructions
Not included:
•Power supply
•Gas hose (outer diameter of hose Ø 4 mm)

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2.3 Description of device
The individual parts of the device are shown and named in the diagram below. These terms
are used throughout the operating instructions.
No.
Component description
1
Module “Standard”(inserted)
2
Piezo element in module (embedded in module)
3
Integration unit (module carrier)
4
Integration unit (driver unit)
5
Fan outlet (cooling driver unit)
6
Fan inlet (cooling driver unit)
7
Interface “Digital I/O“
8
Interface “Module out“
9
Interface “DC in“
10
Interface “Module in“
11
Interface “Gas in“
12
LED status indicator (3 LEDs: Plasma / Warning / Error)
13
Alignment screw for module carrier
14
Mount for module carrier
15
Module “Nearfield”(not inserted)
16
Equipotential bonding terminal
1
2
3
15
4
5
6
10
14
7
11
8
9
12
13
16

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Attention!
The piezo element is an oscillating component that vibrates mechanically at high
frequency. Due to its design, this component cannot be fixed rigidly. For this reason, the
component can lie off-center in the interchangeable modules within certain limits. This is
not an error or quality defect.
Due to the vibration, audible frequencies may also occur under certain circumstances.
This is also normal and not a fault or quality defect.
No.
Component description
17
Connection cable module carrier (8-pin, length 0,3 m)
18
Connection cable DC (3-pin, length 10 m)
19
Connection cable communication (6-pin, length 10 m)
20
Gas hose Ø4 mm outer diameter (not included)
20
18
17
19

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2.4 Connecting lead assignment
The connections of the connection cable DC are to be assigned as followed:
#
Colour
Signal
1
brown
24V DC
3
blue
GND
4
-not connected-
The connections of the connection cable communication are to be assigned as
followed:
#
Colour
Signal
1
brown
Plasma on (Input 0 to 10 V
analog, up to 24V)
2
white
Plasma OK (Outlet 0V / 24V at
max. 20mA)
3
blue
Error (Outlet 0V / 24V at max.
20mA)
4
-not connected-
5
grey
GND
6
-not connected-
Caution –electrical voltage!
The wires may only be connected to the power supply unit or control system
by authorised electrically skilled persons!
Danger due to line voltage. If the power supply unit is visibly damaged:
- Do not start up the machine.
- Replace the damaged parts or have them repaired by a qualified person.