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Operation and Instruction Manual

CNC Two-component Coating Machine

ACW1200

This manual contains critical warnings and cautionary instructions.


It shall be carefully read before starting the use of the equipment.
This manual shall be kept at your hand until the equipment is thrown
away.
In case it is lost or damaged, please contact us or any of our
distributors.
Preface

Thank you very much for choosing our computerized two-component coating
machine (ACW1200).

In order to keep the equipment in the best condition for an extended period,
please carefully read this manual before use. Above all, the specifications,
warnings and prohibitory or cautionary instructions shown herein shall be fully
understood and observed during the use of the equipment.

The equipment covered by this manual is designed for industrial coating work.
It shall be used by those who have been duly trained regarding the handling
and scope of application and have an understanding of the operating
procedure.
Contents

1 For Safety and Correct Use ·························································································· 1


2 Outline of System·······················································································································8
2-1 Outline····························································································································8
2-2 Principles of operation····································································································8
3 Specifications ···························································································································10
3-1 General specifications ··································································································10
3-2 Specifications for ACW1200 control unit·······································································10
3-3 Specifications for ACW mixing unit ···············································································10
4 Main Components ····················································································································12
4-1 ACW mixing unit···········································································································12
4-2 ACW1200 control unit (outside)····················································································12
4-3 ACW1200 control unit (inside)······················································································13
4-4 ACW1200 control unit (bottom ·····················································································13
5 System Construction················································································································14
5-1 Paint circuits ·················································································································14
5-2 Air circuits·····················································································································14
5-3 Electric circuits ·············································································································15
6 Mixing hose······························································································································16
6-1 Parts and functions of mixing hose···············································································16
6-2 Effect of mixing hose length on mixture ratio································································17
7 Two-component Paint and Flushing Fluid ················································································18
7-1 Mixture (two-component paint) ·····················································································18
7-2 Metallic paints···············································································································18
7-3 Flushing fluid ················································································································18
7-4 Ratio by weight and ratio by volume·············································································18
7-5 How to control the hardener ·························································································19
7-6 Spray life and pot life ····································································································19
8 Unpackaging and Installation ···································································································20
8-1 Caution in unpackaging································································································20
8-2 Installation place and caution in installing ····································································20
8-3 Connection of flow meter cables (exclusive) ································································20
8-3-1 Connection to ACW1200 control unit···························································································21
8-3-2 Connection to ACW mixing unit ···································································································21
8-4 Connection of cable A (cable for intrinsically safe explosion-proof solenoid valves) ····22
8-4-1 Connection to ACW1200 control unit···························································································22
8-4-2 Connection to ACW mixing unit ···································································································22
8-5 Connection of cable B (cable for local operation panel) ···············································23
8-5-1 Connection to ACW1200 control unit···························································································23
8-5-2 Connection to local operation panel ····························································································23
8-6 Working in a dangerous area (combustible/explosive atmosphere) ·····························24
8-6-1 Before starting the work ··············································································································24
8-6-2 Working tools·······························································································································24
8-6-3 Grounding ··································································································································24
Contents

8-7 Connection of air hoses ································································································25


8-7-1 Connection to ACW1200 control unit···························································································25
8-7-2 ACW mixing unit··························································································································25
8-7-3 Pilot air between ACW1200 control unit and ACW mixing unit ····················································26
8-7-4 Connection of purging air hose (for the low-pressure type only) ·················································26
8-8 Connection of paint hoses····························································································27
8-9 Flushing the equipment ································································································27
8-10 Feeders ························································································································28
8-10-1 When feeding the fluid at a pressure not higher than 1MPa (for the low-pressure type) ·············28
8-10-2 When using a cylinder pump ·······································································································28
8-10-3 When using a pressurized (paint) tank ························································································28
8-10-4 When using a circulation line·······································································································28

9 Hardener Tank (Optional)·········································································································29


9-1 Hardener tank ···············································································································29
9-2 Flushing the hardener tank····························································································30
10 Preparation of Paint and Compressed Air ················································································31
10-1 Hoses ···························································································································31
10-2 Compressed air supply·································································································31
10-3 Base component supply ·······························································································31
10-4 Hardener supply ···········································································································32
11 ACW Controller ························································································································33
11-1 Description of keys and indicators················································································33
11-1-1 Layout of display ·························································································································33
11-1-2 Detailed description·····················································································································33
11-2 Liquid crystal display (screen map) ·············································································37
11-2-1 Ordinary screens ·························································································································37
11-2-2 Password screen (0001) ·············································································································38
11-2-3 Password screen (0002) ·············································································································38
11-2-4 Password screen (0003)············································································································38
11-2-5 Password screen (0004)··················································・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・39
11-2-6 Password screen (0101) Initialization into the high-pressure mode··········································39
11-2-7 Password screen (0102) Initialization into the low-pressure mode ···········································39
11-2-8 Paint consumption counter screen ······························································································39

12 Parameters ······························································································································40
12-1 Monitors ······················································································································40
12-2 General settings ··········································································································41
12-3 Parameters protected by passwords ···········································································43
12-3-1 Password <0001> ·······················································································································43
12-3-2 Password <0002> ·······················································································································44
12-2-3 Password <0003> ·······················································································································45
12-3-4 Password <0004> ·······················································································································46
12-3-5 Password <0101> ·······················································································································46
12-3-6 Password <0102>······················································································································46
Contents

12-4 Flushing/filling timing charts ·························································································47


12-4-1 Flushing timing chart (for the low-pressure type) ········································································47
12-4-2 Flushing timing chart (for the high-pressure type) ·······································································47
12-4-3 Filling timing chart (for the low-pressure type)·············································································48
12-4-4 Filling timing chart (for the high-pressure type) ···········································································48
12-5 Forced flushing after “Pot Life Time Up” error (flushing by automatic control)··············49
13 Preparation for Operation and Cautionary Notes ·····································································50
13-1 Preparation for operation······························································································50
13-1-1 Power-up procedure and cautionary notes··················································································50
13-1-2 Paint conditions ···························································································································50
13-1-3 Setting the parameters ················································································································51
13-2 Caution in operation ·····································································································51
13-2-1 Mixture in mixing hose·················································································································51
13-2-2 Operation of spray gun················································································································51
13-2-3 Main title screen and operation panel··························································································51
13-3 Regular learning operation ·························································································・52
13-4 To release the mixture pressure ···················································································52
13-4-1 When the local operation panel has not been used·····································································52
13-4-2 When the local operation panel has been used···········································································52
14 Operating Procedures ··············································································································53
14-1 Operation ·····················································································································53
14-2 Mode change from ACW controller···············································································53
14-2-1 Filling the unit with two-component paint (1) (switching from W to 2K (1)) ··································54
14-2-2 Filling the unit with two-component paint (2) (switching from W to 2K (2)) ··································54
14-2-3 Flushing (1) (switching from 2K to W (1)) ····················································································54
14-2-4 Flushing (2) (switching from 2K to W (2)) ····················································································55
14-3 Mode change from local operation panel ·····································································55
14-3-1 Filling the unit with two-component paint (1) (switching from W to 2K (1)) ··································55
14-3-2 Filling the unit with two-component paint (2) (switching from W to 2K (2)) ··································55
14-3-3 Flushing (1) (switching from 2K to W (1)) ····················································································56
14-3-4 Flushing (2) (switching from 2K to W (2)) ····················································································56
14-4 Learning ·······················································································································57
14-4-1 Learning procedure ·····················································································································57
14-5 Mixture ratio test (optional)···························································································58
14-5-1 Mixture ratio test··························································································································58
14-5-2 Procedure for mixture ratio test (optional) ···················································································58
14-6 Changing the mixture ratio ···························································································59
14-6-1 When changing with the system filled with two-component paint ················································59
14-6-2 When setting in the flushing mode ······························································································59
15 Troubleshooting ·······················································································································60
15-1 If any error or alarm occurs ··························································································60
15-2 List of errors and alarms·······························································································60
15-3 Errors ···························································································································61
Contents

15-3-1 How to clear the error indication··································································································61


15-3-2 Detail of errors·····························································································································61
15-4 Alarms ··························································································································62
15-4-1 How to clear the alarm indication ································································································62
15-4-2 Detail of alarm ·····························································································································62

16 Breakdown Drawings ···············································································································67


16-1 ACW mixing unit···········································································································67
16-2 Mixing valve assy (L), Mixing valve assy (H) ·······························································68
16-3 Outer box ·····················································································································69
16-4 Mixing block ·················································································································70
16-5 Flushing valve assembly (L)·························································································70
16-6 Flushing valve assembly (H) ························································································71
16-7 Solenoid valve set ········································································································71
16-8 Air purging assembly····································································································72
16-9 Check valve (female)····································································································72
16-10 Core valve (for mixing valves, R and L)········································································73
16-10-1 Mixing valve, R ····························································································································74
16-10-2 Mixing valve, L·····························································································································74
16-11 Core valve ····················································································································75
16-12 Mixing hose, L (for low-pressure type) ·········································································76
16-13 Mixing hose, H (for high-pressure type) ·······································································76
16-14 Drain valve ···················································································································77
16-15 ACW1200 control unit ··································································································78
17 List of Consumable Parts ·········································································································79
17-1 ACW mixing unit···········································································································79
17-2 ACW control unit ··········································································································79
18 Overhauling and Maintenance ·································································································80
18-1 Mixing valves················································································································80
18-2 Flushing valve assembly ······························································································82
18-3 Flow meter ···················································································································84
19 Inspection Items·······················································································································86
19-1 Pre-work inspection······································································································86
19-2 Inspection after work ····································································································87
19-3 Weekly inspection ········································································································87
19-4 Monthly inspection········································································································88
19-5 Regular inspection········································································································88
19-6 Miscellaneous ··············································································································88
20 Assignment of I/Os···················································································································89
20-1 Inputs and outputs on ALB terminal block ····································································89
20-2 Input and outputs on ACW controller············································································89
21 Settings Recording Sheet ········································································································90
22 Scope of Guarantee·················································································································91
1 For Safety and Correct Use

Contents of this instruction manual shall be fully understood and the instructions shown herein strictly
observed. Using the machine without following instructions in this manual may lead to bodily injury or
damage to properties.

The safety measures described herein are the minimum requirements and additional measures may
also be required. All requirements provided by laws and legislations as well as rules and guidelines laid
by your company or office shall be observed.

The cautionary instructions shown below shall be construed as minimum basic requirements for safety in
the use of our product.

z Cautionary instructions are shown in three levels as defined below.


Calls the user’s attention to a situation that may lead to bodily injury and
WARNING
describes how to avoid that situation.
Calls the user’s attention to a situation that may lead to damage or breakdown
CAUTION
to the equipment and describes how to avoid that situation.

NOTE Gives important or helpful information.

* Please remember that the situation mentioned under CAUTION may also lead to a serious disaster
under certain circumferences. All instructions are important for your safety and prevention of
machine disorder and shall be strictly observed.

1
WARING

Scope of suitable use for the equipment

z For mixed paint coating, the ACW1200 control unit consisting of the ACW controller, exclusive
ACW terminal block (ALB terminal block), flow meter barrier, solenoid valves and other electric
components required for control is used with the ACW mixing unit incorporating a valve system
alternately supplying two components. Do not use them in another composition or for another
purpose than mixing two-component paint.
z The paint, coating conditions and equipment installing conditions shall comply with the
specifications.
z There is a possibility of machine disorder, damage, malfunction, electric shock and fire. Use
the primary power and air supplies complying with the specifications.
z The ACW1200 control unit is not explosion-proof. Never install or operate it in a dangerous
area.
zThe intrinsically safe explosion-proof components include the flow meter and intrinsically safe
explosion-proof solenoid valves. The local operation panel (optional) is also intrinsically safe
and explosion-proof. Do not use other products in a dangerous area.
zDo not wet the ACW1200 control unit, ACW controller or another electric component with any
liquid (water, alcohol, solvent, etc.). Doing so may lead to machine disorder, damage,
malfunction, electric shock or fire.
zNever use any acid or corrosive substance or halogenated hydrocarbon solvent for the ACW
mixing unit or any paint control unit around the equipment.
zIf you have any doubt about the intended use of the product or the paint to be used, please
contact us.
z The use of the equipment under conditions other than specified above is considered as abuse
unless such use is approved by us.

<<General safety instructions>>


z Never apply a fluid or air pressure exceeding the allowable maximum to the equipment during
the coating operation. All components and accessories to be used shall be durable against
the maximum operating pressures mentioned above.
z Check the whole equipment everyday. If any unusual condition is found, turn off the main
power switch and, if the problem can be solved within the specified scope of maintenance work,
repair or replace faulty parts as necessary. If the unusual condition cannot be corrected within
the specified scope of maintenance work, please contact us or any of our distributors for repair.
z To ensure a safe operation of the system, all operators shall read and understand this manual
and labels attached to each unit. The equipment can only be operated by adequately trained
personnel.
z Fire and electric codes and safety related regulations provided by the national or local
government shall be observed during the work.

2
WARNING

Danger from fire, explosion and electric shock

<<Sources of ignition>>

When the paint flows through a pump or hose, it generates static electricity, which may spark at
any part of the coating machine if not properly grounded. Sparks may ignite combustible volatile
components of solvents, particles of sprayed paint, dust suspended in the air and other
combustible substances to cause fire or explosion, resulting in serious injury or damage to the
equipment.
z Always check that the coating machine, the products to be coated and all conductive materials
are correctly grounded
z Do not perform the coating operation in the vicinity of open flame, pilot lamp, drive unit such as
electric motor or engine or another source of ignition.
z Never smoke in or around a spray booth or in the atmosphere containing solvent.
z Adequately ventilate the spray coating place so that it will not be filled with a combustible
(solvent containing) atmosphere generated by the solvent.
z If you feel shocked even slightly by static electricity when handing the coating machine,
immediately stop the coating operation and check that all components are grounded. Never
restart the coating operation until the cause is located and corrective action taken.
z Fire extinguishers with a sufficient capacity must be provided in the place where the spray
coating operation is performed.
z The ACW1200 control unit is not explosion-proof. Do not operate it in a dangerous area.
When using an explosion-proof electric component such as flow meter, local operation panel
(optional) or intrinsically safe explosion-proof solenoid valve, thoroughly read the instruction
manual or specifications for that component before use.
z Do not wet the ACW1200 control unit or another electric component with any liquid (water,
alcohol, solvent, etc.).
zIf the ACW1200 control unit or another electric component generates excessive heat or smokes,
immediately turn off the main power switch to stop the equipment.
z When checking the equipment, never fail to turn off the main power switch on the ACW1200
control unit and reduce the air and paint pressures supplied to the ACW1200 control unit and
ACW mixing unit to zero.
z Do not overhaul or remodel any electric component or ACW controller installed in the ACW1200
control unit.

3
WARNING
<<Grounding>

Class D grounding is required for the equipment (to ensure an electric resistance not exceeding 100
ohms).
The pump, products to be coated and all other coating machine components (in use or around the unit
in use) shall be grounded to prevent accidents from static electricity. If no adequate grounding means
is provided, the grounding work (class D grounding) shall be performed according to the technical
standard for electric equipment.
The coating machine components shall be grounded as specified below.

(1) Grounding the pump


z Attach a grounding wire to the grounding terminal provided at the pump body or car and
connect the other end of the wire to a class D grounding means.
(2) Grounding the hoses
z All high-pressure hoses must be grounded to ground the whole coating system. When
connecting additional hoses for extension, check that each hose is grounded.
z The paint hoses in use shall be checked every week to measure the electric resistance.
The electric resistance shall be 100 ohms or less as obtained with class D grounding. If
the maximum electric resistance is not indicated on the hose, contact the hose distributor
or manufacturer.
Connect an ohmmeter to appropriate part of the hose to measure the resistance and, if it
exceeds the permissible limit, immediately replace the hose with another one.
(3) Grounding the products to be coated
z If hangers and earth clips are contaminated, complete grounding cannot be achieved.
Keep hangers and earth clips clean and conductive (grounded).
(4) Grounding the paint containers
z The containers, if made of a conductive metal, shall be placed on a grounded floor or table.
(5) Grounding the container of solvent used for flushing
z The container, if made of a conductive metal, shall be placed on a grounded floor or table.
Do not place it on a non-conductive sheet such as paper or corrugated cardboard.

<<Safe flushing>>

zBefore flushing, check that the mixing unit, whole coating machine and paint and solvent
containers have been correctly grounded.
zAdequately ventilate the workplace so that it will not be filled with a combustible (solvent
containing) atmosphere.

4
WARNING
Danger from toxic substances
<<Solvents>>
Halogenated hydrocarbon solvents may explode if brought into contact with aluminum or plated
part of a pressure vessel (pump, heater, filter, valve, gun, etc.). The explosion may consequently
lead to fatal bodily injury.
Never use halogenated hydrocarbon solvents.

zExamples of halogenated hydrocarbon solvents


Fluorocarbon group Dichlorofluoromethane and trichlorofluoromethane
Bromine group Ethylene dibromide, chloromethylene bromine and methyl bromide
Iodine group Butyl iodide, methyl iodide, ethyl iodide and propyl iodide
Chlorine group Pentachlorocarbon, chloroform and dichloroethylene
Chloromethylene and
Monochlorobenzene, orthodichlorobenzene and perchloroethylene
dichloroethane group
Trichloroethane group Trichloroethylene and monochlorotoluene
(The above list does not include all halogenated hydrocarbons. For detail, contact the paint
distributor or manufacturer.)

<<Influences on the human body>>

If a solvent containing atmosphere or fluid comes into contact with your eyes or mouth or a toxic
substance is inhaled or swallowed and brought into your body, your nervous tissue may be
destroyed to cause serious injury such as lifetime functional disorder. Immediately ask for
adequate medical treatment.

Necessity of medical treatment


Immediately receive medical treatment by a medical specialist such as orthopedist, not by
a layman. At this time, you should tell him (her) the exact type of the paint you used.

z You may lapse into dyspnea or be poisoned by organic solvent in the mist of paint or spraying
atmosphere. Do not use the equipment in a closed room, tunnel, tank or another poorly ventilated
place. The user shall take enough care of persons and livestock around him as well as himself.
z The isocyanate used for two-component paint may hurt mucous membranes in your noise or throat.
You should be acquainted with components of the paint, hardener, solvent and other volatile
substances to be used. If you need further information, contact the paint or solvent manufacturer.
z When doing the spray coating work, always wear the protective goggles, working clothes and mask
recommended by the paint or solvent manufacturer. Additional protective devices may be required
depending on the paint components or ventilation level. Contact the paint or solvent manufacturer.

5
WARNING

Danger from spray and pressures

This system uses the paint under a very high pressure. Therefore, the spray gun is filled with the
highly pressurized paint. If the sprayed or leaking paint hits a person at a close distance, it huts his
skin and a lot of toxic substances penetrate into his body. If he fails to receive adequate medical
treatment, his nervous tissue may be destroyed to cause serious injury such as lifetime functional
disorder or surgical amputation of damaged part of his body. You may be seriously injured if the paint
is only pinged into your eyes or skin.

Necessity of medical treatment


If you are hit by the sprayed paint, immediately receive medical treatment by a medical
specialist such as orthopedist, not by a layman. At this time, you should tell him
(her) the exact type of the paint you used.

zNever aim the head of a spray gun to your body or another person or draw any part of your body near
the spray.
zNever cover the nozzle of the spray gun with your finger, palm or another part of your body.
zDo not start using the system before fully understanding how to operate it.
zBefore using the system, always make sure that hose joints and all connections in the paint circuit are
tight. Above all, check that joints of the hoses that move during operation are locked tight.

<<Safety device on spray gun>>

zEach spray gun is provided with a safety device. Before using the spray gun, make sure that the
safety device correctly functions.
zDo not remove or modify any part of a safety device. Doing so may lead to a malfunction or injury.
zUse the spray gun according to the instruction manual provided with it.

<<For safety against nozzle>>

zDo not put your finger, palm or any article in your hand onto the nozzle.
zTake special care when cleaning or replacing the nozzle. If the nozzle is clogged during the spraying
operation, immediately fasten the safety lock on the gun trigger, reduce the paint and air pressures to
zero and remove the nozzle for cleaning. It is dangerous to start removing the paint sticking around
the nozzle before fully releasing the pressures or with the trigger not locked.

6
WARNING

<<Safety of hoses>>

z Handle hoses with much care. Be sure that hoses are not caught or pulled by another object or
brought into contact with sharp edges.
zDo not bend or collapse any hose. Doing so raises the pressure in the hose and possibly breaks the
hose to cause the paint to be injected in a dangerous manner.
zDo not expose hoses to temperatures higher than 50 deg C or lower than -20 deg C.
zBefore starting the equipment, always make sure that hose joints and all connections in the paint circuit
are tight. Above all, check that joints of the hoses that move during operation are locked tight.
zDo not pull any hose to drag or move the equipment.
zNever use any damaged hose. Check each hose throughout its length for scars, leak, wear, swells,
cracks and loose fittings. In any of them is found, immediately withdraw the hose from service and
replace it with a new one.
z Any hose with paint leak must be replaced with a new one. Use a standard hose complying with our
specifications.

<<Danger from misuse of the equipment>>

z When checking or cleaning the spray gun, ACW mixing unit or another component, reduce the paint
and air pressures to zero to prevent accidental starting of the pump.
z Do not move the equipment when it is under pressure.
z Never apply a fluid or air pressure exceeding the allowable maximum to the equipment during the
coating operation. All components and accessories to be used shall be durable against the maximum
operating pressures mentioned above.
z To ensure a safe operation of the system, all operators shall read and understand this manual and
labels attached to each unit. The equipment can only be operated by adequately trained personnel.
z Fire and electric codes and safety related regulations provided by the national or local government
shall be observed during the work.

7
2 Outline of System

2.1 Outline
Different from the conventional volume type simultaneous pumping to the mixer, this system employs new
metering and mixing systems, in which each of the base material and hardener is precisely measured and fed
alternately into the mixer by the computer control.
Necessary quantities of the base component and hardener are very precisely metered by flow meters and
alternately fed into the mixing hose where the base component and hardener are mixed into a single fluid
(primary mixed paint). After that, the primary mixed paint is sent into the static mixer for complete mixing and
then fed into the spray gun.
Once necessary parameters are defined, the mixture can be sprayed only by switching on with the mode
button. The parameters are divided into two groups; the ones related with the equipment conditions and the
ones frequently used such as mixture ratio and flushing time, all of which are protected by passwords.
The mixture ratio, flow rate, quantities of the base component and hardener put into the system, the remaining
time of pot life, etc. are very clearly indicated on the ACW controller.

2-2 Principles of operation


In this system, two components are metered and mixed as long as the spray gun is on (spraying) and the
base component and hardener mixing valves close to stop the mixture control when the gun is off (see
Figure 2.2.1).
(1)When the READY switch is “ON” on the main screen, the mixture and color change controls are
available. With the READY switch “OFF,” the mixed paint is not sprayed even if the spray gun trigger is
pulled.
(2)As the spray gun trigger is pulled, the ACW controller activates the hardener mixing solenoid valve to
start feeding the hardener.
(3)The hardener is fed through the flow meter to the mixing hose (see Figure 2.2.2).
(4)The ACW controller controls the mixing valve according to the signals sent from the flow meter to obtain
the calculated target flow rate and accurately meters the hardener fed into the mixing hose.
(5)After feeding of the hardener is completed, the base component mixing valve is activated to feed the
base component in the similar manner (see Figure 2.2.3).
(6)Those steps are repeated to alternately feed the base component and hardener into the mixing hose.
(7)The primary mixture prepared in the mixing hose is fed into the static mixer where it is thoroughly mixed
and then sent into the spray gun.
(8)When the spraying operation is stopped, the mixing valves under operation are closed. (At this time,
both of the base material and hardener mixing valves are closed). When it is started again, the mixing
valves are opened to start mixing. Because both mixing valves are closed as soon as the spraying
operation is stropped, there is no possibility of the reverse flow that may lead to hardening in the
mid-line.
(9)The pot-life counter starts counting down right after the system is filled with the two-component paint.
As the spray gun trigger is pulled and the resetting point (flow rate) is reached, the pot-life counter is
reset for restarting. In short, the count-down continues as long as the mixture is left unused for
spraying. During the flushing process at the end of coating work, the pot-life counter does not count
down.

8
Fig. 2.2.1

(9)
On Restarted
READY switch (1)
On On
Spray gun (2)
On On On On On On
Hardener (3)
On On On On On On
Base component
B A
(5)
Mixture ration A:B
Spray on Spray off Spray on

Mixture ratio Mixture ratio Mixture ratio


(6) (9)
Mixture ratio control on control off
(7) control on control on
(8)
System stopped

(1) Indicates the on/off status of the READY switch on the ACW Controller.
(2) Indicates the status of signals from the spray gun trigger.
(3) Indicates the hardener supply status (or the status of the hardener mixing valve).
(4) Indicates the base component supply status (or the status of the base component mixing valve).
(5) Indicates the mixture ratio.
(6) Indicates that the base component and hardener are alternately supplied.
(7) Indicates that the spray is not working. Both mixing valves are closed to stop the mixture ratio control.
(8) Indicates that the READY switch is “OFF” and the control has been reset. (The pot-life counter is not
reset.)
(9) Indicates that the READY switch is “OFF” and hardener has been supplied to restart the control.

Base component
Hardener flow meter
flow meter

Hardener
mixing
valve

Base component
mixing valve

Mixing hose Mixing hose

Fig. 2.2.2 Fig. 2.2.3

9
3 Specifications
Specifications

3-1 General specifications


Model: ACW1200
Mixing ratio range: 1:1 to 30:1 *(1)
Mixture control accuracy: ±5% or less *(1)
Components of paint: A type of base component and a type of hardener
Viscosity ranges: 25mPa-s to 300mPa-s for base component/hardener (for low-pressure type) *(2)
25mPa-s to 3000mPa-s for base component/hardener (for high-pressure type) *(2)
Flow rate ranges: 100 to 1000 ml/min for type 1 (for low-pressure type) *(3)
200 to 2000l/min for type 2 (for high-pressure type) *(3)
Compressed air pressure: 0.4 MPa to 0.7 MPa

3-2 Specifications for ACW1200 control unit


Designation: ACW1200 control unit (ACW controller)
Model: ACW1200CUT
Operating conditions: Temperature: 0 to +40°C
Humidity: 10 to 80 %, No condensation allowed.
Operating atmosphere: No exposure to corrosive gas, dust, vapor, dripping water and direct sunlight allowed.
Transporting and storing conditions:
Temperature: -10 to +50°C
Humidity: 10 to 90 %, No condensation allowed.
Supply voltage: 100VAC±10%, 50 to 60Hz
Current consumption: 3A
Weight: 30kg
Dimensions: 400mm wide x 400mm high x 250mm deep *(4)
Explosion protection: Non explosion-proof

3-3 Specifications for ACW mixing unit


Designation: ACW mixing unit
Model: ACW1200 MUT-L (low-pressure type) or ACW1200 MUT-H (high-pressure type)
Withstanding pressure of paint circuit:
25MPa (for high-pressure type) or 1.5MPa (for low-pressure type) *(5)
Paint supply pressure: Shall be at least three times the pressure required for spraying
for the low pressure type. *(5)
Materials of devices in contact with mixture:
Tungsten carbide, stainless steel, Teflon or polyacetal
Usable paint: Solvent based two-component urethane paint for finish coat or epoxy paint *(6)
Weight: 30kg
Dimensions: 350mm wide x 385mm high x 301mm deep
Explosion protection: Intrinsically safe and explosion-proof

10
(flow meter, solenoid valves, local operation panel) *(7)
Equipment components: (1)ACW mixing unit
<Mixing valves, flow meters, flushing valve assembly, drain valves, outer box
and intrinsically safe explosion-proof solenoid valves (for mixing valves)>
(2)ACW1200 control unit (control panel)
<ACW controller, buzzer, lamp (red), power switch, non explosion-proof
solenoid valves (for flushing valve assembly and drain valve)>
Other requisites: (1)Two flow meter cables
(2)One Cable A (between ACW1200 control unit and ACW mixing unit)

Other necessary items: (1)Base component, hardener and flushing pumps and pump supports
(2)Paint regulator (for base component/hardener and for flushing)
(3)Paint hoses and air tubes
(4)Spray gun and nozzle
(5)Nitrogen gas bomb (w/pressure reducing valve) and gas piping work

Options: (1)Local operation panel (provided in the booth for mode selection)
(2)Stand

Miscellaneous: (1)Enclosed stainless steel tanks (10 liters, 20 liters, 40 liters and 60 liters)
(2)Lower limit level sensors for tanks (non explosion-proof or explosion-proof)

Notes
*(1) The mixture control accuracy depends on the conditions of use including the paint viscosity and
flow rate.
*(2) For the paint with a viscosity above 100mPa-s (30 seconds/FC#4), the pump pressure shall be
0.6MPa or higher (for the low-pressure type).The specified mixture control accuracy cannot be
maintained with a viscosity below 30mPa-s (12 seconds/FC#4).
*(3) For the paint with a viscosity below 30mPa-s (12 seconds/FC#4), the flow rate may not be
controlled within this range. The flow rate during the fill-up shall not exceed the specified limit.
*(4) The size of the control panel excluding pneumatic devices.
*(5) For the low-pressure type, the pressure loss through the mixing unit is about 15MPa.To ensure a
stable flow rate, the paint supply pressure shall be three times the pressure required for spraying.
The tripled pressure shall not exceed the maximum withstanding pressure of the paint circuit.
*(6) Use a flushing fluid with sufficient solubility. See 7-3 Flushing fluid. Water-based paints cannot
be used. Some metallic paints and special paints containing rough particles may not be used.
See 7-2 Metallic paints.
*(7) All components and electric devices are not explosion-proof.

11
4-1
4ACW mixing unit
Main Components

Components of the unit are illustrated below with a basic assembly arrangement.
Intrinsically safe
explosion-proof solenoid
Outer box valve (for hardener)

Flow meter
(for hardener)

Intrinsically safe Mixing valve


explosion- proof solenoid (for hardener)
valve (for base component)

Air inlet (G1/4)


(for intrinsically safe explosion- Air purging valve
proof solenoid valves) (installed for low
pressure type only)
Flow meter
(for base component)
Mixing valve
(for base component)

Drain valve
(for safety device) Thinner valve
Mixture outlet

4-2 ACW1200 control unit (outside)

Filter regulator Power switch


(for spray gun)

Error/alarm lamp (red)

Buzzer

Air outlet
(for spray gun) ACW controller

Power cable Bracket


(100 VAC)

Pilot air supplies

x For air buzzer (local operation panel)


x For drain
x For air purging (for low pressure type only)
x For thinner

12
4-3 ACW1200 control unit (inside)

Power circuit breaker 24VDC power supply

ALB terminal block


(Terminal block Flow meter
exclusive for ACW ) barrier relays

100VAC outlet

Local operation
panel barrier
Solenoid valve (non
explosion-proof)
Intrinsically safe
100VAC outlet explosion-proof
(exclusive for BPS)*1 solenoid valve
barrier (for mixing
valves)

*1. The 100VAC outlet is used to supply power to our BPS controller, etc. Do not use it for another
application. The power supply is shut off during a flush or when the flushing fluid (thinner, etc.) is
selected.

CAUTION
There is a possibility of machine disorder or malfunction.
Do not use the outlet for electrostatic controller for other purposes than controlling the BPS
controller.

4-4 ACW1200 control unit (bottom)

Cable hole (5)


w/grommet (rubber cap)
M8 screw
(for mounting a bracket)

13
5 System Construction

5-1 Paint circuits


The base component, hardener, flushing pump (feeder), spray gun, paint and air hoses and nitrogen gas
(N2 gas) shall be separately prepared for use with this system.

Hardener
regulator *1
Hardener feeder *2
N 2gas

Enclosed SUS tank Base component


regulator

Base component
feeder *2
Spray gun

Mixing hose
Paint hose

Paint hose
Flushing fluid feeder
*2
Flushing fluid Paint hose
regulator Static mixer
Compressed
air supply

*1. For the pressure gauge of the hardener regulator, a diaphragm type shall be used to prevent
hardening.
*2. For pump specifications, see 8-10 “Feeders.”

5-2 Air circuits

ACW1200 control unit ACW mixing unit


Local operation
panel (optional)

Pilot air tube Compressed


Compre
air supply
ssed air
supply Pilot air tube
Pilot air tube Compressed
*1
air supply
Pilot air tube
(For purging air)
Atomization air hose
Spray gun *2
Non-dangerous zone
Dangerous zone
*1. For the purging air, see 8-7-4 “Connection of purging air supply” (for the low-pressure type only).
*2. For the spray gun, see 8-7-1 “ACW1200 control unit.”

14
5-3 Electric circuits
In this system, the ACW controller detects signals from the flow meters and accordingly controls the mixing
valves using the pilot air through the intrinsically safe explosion-proof solenoid valves. The electric
circuits are illustrated below.

ACW1200 control unit ACW mixing unit


Local operation
panel (optional)

Cable B
(for local operation panel)
*2
Cable A (for intrinsically safe solenoid valves)
*1
Flow meter cable (for hardener)
Flow meter cable (for base component)
Power outlet
Non-dangerous
zone Dangerous zone

*1. For the flow meter cables, see 8-3 “Connection of (exclusive) flow meter cables.”
*2. For cable A, see 8-4 “Connection of cable A (cable for intrinsically safe explosion-proof solenoid
valves).”
*3. For cable B, see 8-5 “Connection of cable B (cable for local operation panel).”
*4 For the part No. and length of each cable, see the following table.

z Part Nos. and specifications for cables


Part name Part No. Quantity Length Specifications

390A-001 10m
390A-002 20m Cables exclusively used for flow meters.
Flow meter cable 390A-003 2 30m Commonly used for base component and
hardener.
390A-004 40m
390A-005 5m
390C-001 10m

Cable A (for 390C-002 20m


Cables for intrinsically safe explosion-proof
intrinsically safe 390C-003 1 30m solenoid valves in ACW mixing unit.
solenoid valves)
390C-004 40m
390C-005 5m
390E-001 10m

Optional 390E-002 20m


Cables exclusively used for optional local
Cable B (for local 390E-003 1 30m operation panel.
operation panel)
390E-004 40m
390E-005 5m

15
6 Mixing hose

The mixing hose serves to rectify the flows of the alternately supplied base component and hardener to
ensure complete mixing by the static mixer.

6-1 Parts and functions of mixing hose

Mixing hose
From “2KOUT” on
mixing unit

Mixture flowing direction

Flows of alternately
supplied base component
Static mixer and hardener are rectified
Connected to spray gun here (standard length =
3m)

Rectified flows of two


components are mixed here.

Mixture is further mixed here.

The figure shows <4433> for low pressure as a model.

CAUTION
Poor mixing or hardening in the mid-line may occur.
zIf the hose length to the static mixer is too small, the paint cannot be thoroughly mixed by the
static mixer, possibly resulting in poor hardening. Do not reduce the hose length to the
static mixer or change the hose diameter.
zThe hose portion downstream the static mixer also serves to ensure the mixture quality. Do
not directly connect the static mixer to the spray gun.

16
6-2 Effect of mixing hose length on mixture ratio
The hose length to the static mixer has an effect on the mixture ratio. To achieve a larger mixture ratio,
the hose length from the static mixer to the spray gun shall be increased.
Adjust the hose length according to the following chart.

(m)

Hose,
4mm in ID

Hose,
6mm in ID

(ratio)

Mixing is permitted with standard mixing hose in this range

(Example) To achieve the ratio of 12:1


The mixing hose shall be 7m long. This means that the hose length from the static mixer shall be changed
to 4m. See 16-12 “Mixing hose L.”
See the following table for extension hoses. Cut them to a necessary length before use.

Hose Part No. Remark

570-0050 For φ6-4


5m
52C-0050 For φ8-6
Mixture flowing direction
570-0100 For φ6-4
10m
52C-0100 For φ8-6 Length fixed
Static mixer to 3m

4m Mixing hose, 7m long

17
7 Two-component Paint and Flushing Fluid

7-1 Mixture (two-component paint)


As shown in Figure 6.1, the velocity of the fluid is higher at the Flow direction
central area in the pipe and almost zero along the inside
surface of the pipe wall. The paint as mixed with isocyanate or
reactor (hardener), which has been in contact with the moisture
in the air, initiates a chemical reaction and accumulates on the
pipe wall just like cholesterol to make the pipe narrower and
finally clog it. Fig. 6.1
Therefore, it is important to control the hardener and keep the
devices and pipes in contact with the mixture thoroughly clean.
Isocyanate, a chemical agent used for the two-component paint, may hurt mucous membranes in your
nose or throat. Put on a face mask for protection from organic solvents during the work. Additional
protective devices may be required depending on the paint components or ventilation level. Contact the
paint or solvent manufacturer.

7-2 Metallic paints


General metallic paints may be used but some metallic paints and special paints containing rough particles
(pearly paints) may not be used because the particles may clog the precision geared flow meters, which
have very small clearances, and make the mixture control impossible.
When using any of such paints, communicate properties of the paint to our sales personnel and perform a
test run in advance. When using a paint not used before, do not directly use it on the line but perform a
functional test using the equipment to check the mixing, washing and color change functions and verify the
coating quality with coated samples.

7-3 Flushing fluid


For cleaning the base component and hardener circuits and hardener tank, use a flushing fluid specially
provided for two-component paints. Do not use any lacquer or alcohol based solution, solution containing
much alcohol or collected and recycled solution.

CAUTION
There is a possibility of machine disorder, malfunction or hardening in the mid-line.
z Do not use any lacquer or alcohol based solution for flushing the equipment. It reacts with
the mixture or hardener and accumulates in the flow meters and mixing valves in the
equipment and on inside surfaces of paint hoses just like cholesterol to cause a machine
disorder and gel the fluid in circuits. Always use an exclusive flushing fluid recommended
by the paint manufacturer.
z Do not use any collected and recycled solution for flushing the equipment.

7-4 Ratio by weight and ratio by volume


This system controls the flow rates by volume. To convert a ratio by weight to that by volume or the
weight of the paint sampled for mixture ratio test (optional) to a volumetric value, calculation is required
using the specific gravity of the paint.
(1) Calculation of mixture ratio (by weight → by volume)
Mixture ratio (by volume) = Weight of base component / specific gravity of base component :
weight of hardener / specific gravity of hardener
(2) Calculation of sampled paint quantity (weight→ volume)
Volume of sampled paint (ml) = Weight of sampled paint (g) / specific gravity

18
7-5 How to control the hardener
When an isocyanate based hardener comes into contact with the moisture (OH group) in the air or another
solution, it generates an invisible substance (crystal dust). In the initial stage of reaction between the
hardener and OH group, no effect of the crystal dust is observed with eyes. But, after a certain time, it is
increasingly hardened and sticks to or accumulates on inside surfaces of pipes where the fluid flows slowly.
If it is sent to the system, it may affect the performance. Therefore, the following steps must be taken to
control the hardener.
(1) To keep the hardener out of contact with the air as far as possible, use an exclusive tank capable of
sealing in nitrogen gas.
(2) We do not take responsibility for the machine disorder or clogged circuit or flow meter due to the
crystal dust or hardened wastes generated when the hardener is not controlled with nitrogen gas. If
nitrogen gas is not available, the compressed air may be dried by passing it through an air dryer
(heated after cooled) and an air filter containing silica gel. In this case, however, the equipment
shall be used at the customer’s risk.
(3) Use stainless steel pipes and Teflon hoses, which are slow to absorb moisture or air, to feed the
hardener. In an absorptive nylon hose or easily oxidized iron pipe, the hardener quickly reacts and
hardens even if the circuit is apparently enclosed. Especially in hot, moist seasons, the hardener is
cured within a day in such a hose or pipe.

CAUTION
There is a possibility of machine disorder, malfunction or hardening in the mid-line.
zThe hardener shall be kept out of contact with the air.
zThe hardener shall be stored in an exclusive sealable tank with the air replaced with nitrogen gas.

7-6 Spray life and pot life


(1) Spray life: A length of time in which the mixture can be sprayed to obtain a desired coating quality.
(2) Pot life: A length of time from the point of mixing to the point when the mixture is hardened (gelled).

Longer
Pot life
Mixture viscosity

Spray life

Spray life

Shorter
Time Lower Temperature Higher

The viscosity more quickly increases after the end of the spray life, in general.
The spray life becomes shorter with the increase of the air and fluid temperatures.

19
8 Unpackaging and Installation

This equipment is 100% inspected at the manufacturer’s factory and supplied with the paint hoses, spray
gun, power supply, compressed air and paint (base component and hardener) for immediate use after
delivery. However, some parts may be damaged or lost during transportation. After unpackaging,
please check carefully for missing or damaged parts and, if any, contact us or any of our distributors.
See 5 “System Construction.”

8-1 Caution in unpackaging


(1) Check each unit for broken fittings and screws and for gouges and dents around the periphery.
(2) Check the electric components in the ACW1200 control unit and remount them if disconnected.
(3) Tighten loose bolts, nuts and joints if any.
(4) Check the air pressure gauge for damage and replace it with a new one if necessary.

8-2 Installation place and caution in installing


(1) The ACW1200 control unit is not explosion-proof. It cannot be installed in a dangerous area.
(2) Class D grounding work is required for all pumps, ACW1200 control unit and ACW mixing unit.
(3) The ACW mixing unit and local operation panel (optional) are intrinsically safe and explosion-proof.
They can be installed in any place other than class 0 dangerous areas. When installing any device
other than above, thoroughly read the instruction manual for that device before use and, if you need
further information, contact the manufacturer or distributor before installation.
(4) Each unit shall be installed with enough space reserved around it for routing of the paint hoses and air
tubes and for ease of maintenance.
(5)Vibration and noise give an adverse effect on the flow meters and may prevent accurate mixture control.
The ACW mixing unit shall be secured on a rigid foundation and installed at least 1m apart from
sources of noise such as robots.
(6) Never apply a tensile force to a power cable (to the flow meter, etc.), air tube or paint hose or collapse it
with a heavy object.

8-3 Connection of flow meter cables (exclusive)

CAUTION
There is a possibility of malfunction.
z If the flow meter cables are affected by noise, this may be indicated as an error by the ACW
controller, possibly resulting in a line suspension or malfunction. Always use shielded wires
and ground them to prevent noise.
z A malfunction due to noise is considered to exist if the hardener or base component flow rate
is counted up on the ACW controller display when the spray is not on.

20
8-3-1 Connection to ACW1200 control unit
(1) Remove the grommets at the bottom and firmly mount the glands of the flow meter cables.
(2) Open the door and connect the cables to the connectors marked as For Base Component and For
Hardener respectively.

Nut

For base
component or
hardener

Cable gland

(2)
(4)
(1) Remove the grommet (3) Connect to the connector
Remove the nut from from the control panel Fully tighten the nut onto marked as “For Base
the cable gland. and insert the cable into the cable gland. Component” or “For
the cable hole (φ22mm). Hardener.”

8-3-2 Connection to ACW mixing unit


(1) Open the unit and connect the cable connectors to the flow meters.
(2) Install two flow meter cables. The cable for base component and that for hardener have the same
shape and care shall be taken to prevent wrong connection of the cables from the ACW 1200 control
unit.

Hardener flow meter

Base component flow meter

21
8-4 Connection of cable A (cable for intrinsically safe explosion-proof solenoid valves)
Cable A may be installed in either direction. It has connectors of the same shape at both ends.

8-4-1 Connection to ACW1200 control unit.


(1) Remove the grommet at the bottom and firmly mount the gland of cable A.
(2) Open the door and connect the cable to the connector marked as For Solenoid Valve.

Nut

Nut
For
solenoid For
valve solenoid
valve
For
solenoid
valve

Cable gland

(2)
(1) Remove the grommet (3) (4)
Remove the nut from from the control panel Fully tighten the nut onto Connect to the connector
the cable gland. and insert the cable into the cable gland. marked as “For Solenoid
the cable hole (φ22mm). Valve.”

8-4-2 Connection to ACW mixing unit


(1) Remove the cover and the lid for intrinsically safe explosion-proof solenoid valve.
(2) Open the unit and firmly mount the gland of cable A in the cable hole.
(3) Connect the connectors. When installing the lid, take care not to entangle any cable.

(1) (2) (3)


Remove the cover and the lid for Open the unit and firmly mount the Connect the connectors. When
intrinsically safe explosion-proof gland of cable A in the cable hole. installing the lid, take care not to
solenoid valve. entangle any cable.

22
8-5 Connection of cable B (cable for local operation panel)
Cable B may be installed in either direction. It has connectors of the same shape at both ends.

8-5-1 Connection to ACW1200 control unit.


(1) Remove the grommet at the bottom and firmly mount the gland of cable B.
(2) Open the door and connect the cable to the connector marked as For Local Operation Panel.

Nut

Nut

For local
For local
operation
operation
panel
panel
For local
operation
panel

Cable gland

(2) (4)
(1) Remove the grommet (3) Connect the cable to the
Remove the nut from from the control panel Fully tighten the nut onto connector marked as
the cable gland. and insert the cable into the cable gland. “For Local Operation
the cable hole (φ22mm). Panel.”

8-5-2 Connection to local operation panel


(1) Remove the grommet at the outer box and firmly mount the gland of cable B in the cable hole.
(2) Remove the lid and connect the connectors. When installing the lid, take care not to entangle any
cable.

Nut
Local Operation Panel For local
READY WASH (W) operation panel
OFF ON SOLVENT 2K

START

(2) (3)
(1) Connect the connectors. When
Remove the lid and firmly
Remove the grommet at the outer installing the lid, take care not to
box. mount the gland of cable B in
entangle any cable.
the cable hole.

23
8-6 Working in a dangerous area (combustible/explosive atmosphere)
When installing the equipment in a dangerous area such as inside of the booth, the following instructions
shall be observed. A difference of an explosion-proof device from general ones is that it requires “safety
check” before use.

WARNING

To prevent injury
z Never remodel the equipment or use a combination of units other than specified as doing so may
lead to an accident. If remodeling or structural change is required, please contact the responsible
personnel of us.

To prevent fire and explosion


z Check that all units have been completely grounded.
z Adequately ventilate the workplace so that it will not be filled with a combustible (solvent containing)
atmosphere.

8-6-1 Before starting the work


(1) The grounding work according to the “Guidelines for Electric Equipment Protection against Explosion at
Factories” is required for the equipment and all devices and tools used for operation, maintenance and
servicing of the equipment in a “dangerous area” where, for example, a combustible (explosive)
atmosphere exists.
(2) When directly involved in the work in a place where a combustible (explosive) atmosphere exists, all
operators shall have full knowledge about the explosion prevention and electric work and fully check
the safety of everything including the devices and tools to be used and (anti-static) working clothes.

8-6-2 Working tools


(1) The tools connected with an “outlet” when used, e.g. power drills and illuminators, must be checked
before work. Scared, thinned (elongated), swelled or otherwise deformed cables must be always
checked for.
(2) Perform a continuity test using an ohmmeter between metallic part or grounding terminal of each tool
and the power cable terminal and ground the tool before use.
(3) The outlet used in a dangerous area must be equipped with an interlock to open or close contacts
after a given delay. A capability of making electric circuits completely continuous or open when the
plug is inserted or removed is a precondition for the explosion-proof equipment.
(4) A power supply intermittently connected to a tool may become a source of ignition. Preventive
measures against human errors and correct operating procedures shall be strictly observed in working.

8-6-3 Grounding
For the equipment installed in a dangerous area such as inside of the booth (e.g. ACW mixing unit and
local operation panel), the main body and grounding terminals (e.g. terminals provided in the spray booth)
shall be grounded according to the “Guidelines for Electric Equipment Protection against Explosion at
Factories.”
(1) A continuity test shall be performed between the main bodies of the ACW mixing unit and local
operation panel (optional) and the grounding terminals to check that there is a continuity meeting the
standard for class D grounding.

24
(2) Thoroughly read the paragraph of “Grounding” in section 1 “For Safe and Correct use” before starting
the work.
8-7 Connection of air hoses
8-7-1 Connection to ACW1200 control unit

(1)Install the attached filter regulator.


(2)Connect the air hose coming from the compressor to the air
cock (G1/4 screw) on the filter regulator 1. 1
(3)The air hose for the spray gun shall be connected with the
2
cock 2. Adjust the pressure applied to the spray gun with
the filter regulator.
(4)The compressed air supply shall be separately connected
from other driving air supplies so that the air flow switch will
not be activated when the spray gun is not in use.
(5)It is recommended to use air hoses not smaller than 3/8 inch
(8mm) in inside diameter.

NOTE
The compressed air for spray gun shall be taken from the cock mentioned above.

The air supply on/off control for spray gun is linked with the mixing switch.

8-7-2 ACW mixing unit


(1) Connect the air hose from the compressor to the joint (G1/4 screw) 1.
(2) The air pressure shall be 0.4MPa or higher. It is recommended to install an air regulator as necessary.

25
8-7-3 Pilot air between ACW1200 control unit and ACW mixing unit
(1) Connect the attached φ6 air tubes (usually three tubes, but two in the case of a high-pressure type)
according to the nameplate.
(2) For the high-pressure type, two tubes are attached. In this case, no tube is installed for air purging.
(3) The attached air tubes are 20m long. Cut or extend to a desired length if necessary.

ACW mixing unit ACW1200 control unit

Drain
Air purge
Thinner

φ6 air tubes

No tube is to be installed in the
case of a high-pressure type.

8-7-4 Connection of purging air hose (for the low-pressure type only)

The purging air valve is mounted on the ACW mixing unit (for the
low-pressure type). Connect the air hose with the following
procedure.
(1)Open the unit and connect the air hose coming from the
compressor to the joint (G1/4 screw) 1.
1
(2)The purging air to be supplied shall be adjustable in pressure
and free of oils and debris.
(3)It is recommended to provide an air filter at the purging air
supply to prevent intrusion of the paint in case it flows
reversely.
(4)The purging air hose to be installed shall be transparent and
resistant to solvent.

CAUTION
There is a possibility of machine disorder, malfunction and paint leak.
z The air purging valve joint contains a check valve to prevent intrusion of the paint into the air
circuit in case it flows reversely due to a disorder of the valve or for another reason. Do not
remove the check valve or replace it with another part.

26
8-8 Connection of paint hoses
(1) Connect the hose joint at the paint outlet on each pump (feeder) and that at the paint regulator.
(2) Connect the paint hoses coming from the paint regulator to the ACW mixing unit.
(3) For the hardener, use a Teflon hose with a stainless steel cap.
See 10 “Preparation of Paint and Compressed Air.”
8-9 Flushing the equipment
After the location of each unit is determined and the air and paint hoses are connected, flush the paint
circuit and equipment (circulate the flushing fluid).

WARNING
To prevent danger from toxic substances and compressor
z When working, wear a face mask, safety goggles and protective clothes for protection
against organic solvents.
zAdequately ventilate the workplace so that it will not be filled with a combustible (solvent
containing) atmosphere.

To prevent fire and explosion


z Check that all units have been correctly grounded.

CAUTION
There is a possibility of machine disorder, malfunction, or hardening in the mid-line.
z Failure to flush leads to the outflow of wastes, etc., which clogs the flow meters to cause a
malfunction or damages the valve or check valve seat, resulting in a reverse flow of the paint.
Never fail to flush.
z For the flushing fluid, do not use any lacquer or alcohol based solution, solution containing
much alcohol or collected and recycled solution. See 7-3 “Flushing fluid.”

(1) Flushing the pumps (feeders)


Suck the flushing fluid through the suction port and open the pump drain to circulate the flushing fluid.
Flush all feeders.
(2) Flushing the paint circuits
After flushing each pump (feeder), remove the paint hoses connected to the ACW mixing unit and
wrap a clean cloth around the loose end of each paint hose and run the pump to drain the flushing
fluid and remove debris, etc. in the hose. Flush the flushing pump in the same manner.
(3) Flushing the base component container
Chips and other particles stick to the inside surface of the container. Carefully wash them using a
waste cloth or brush.
(4) Flushing the enclosed SUS tank for hardener (optional)
See 9-2 “Flushing the hardener tank” and 7-3 “Flushing fluid.”
(5) Flushing the paint filter
After flushing, never fail to overhaul and clean the paint filter and other filters.

27
8-10 Feeders
The fluid may be fed from a pneumatic pump, pressurized tank (paint tank) or circulation line. When
feeding the fluid, follow the procedure described below.

8-10-1 When feeding the fluid at a pressure not higher than 1MPa (for the low-pressure type)
(1) Each feeder shall have a capacity not lower than three times the flow rate and delivery pressure
required for the spray gun.
If a spray gun delivery pressure of 0.2MPa is required, it is necessary to ensure a stable pressure
not lower than 0.4MPa at each paint valve of he ACW mixing unit although depending on the length
and inside diameter of the paint hose to be connected and the viscosity of the paint. Therefore, a
feeder capable of feeding at 0.6MPa or higher is required.
(2) The feeder shall be capable of generating a fluid pressure not lower than 0.6MPa for the paint with a
viscosity between 80 and 100mPa-s or not lower than 1.0Mpa for the paint with a viscosity not lower
than 100mPa-s.
(3) It is desirable to install the paint regulator and paint pressure gauge in the paint circuit consisting of a
2m or shorter hose from the CCV of the ACW mixing unit.
If the pressure is regulated at the outlet of the pump, it may significantly drop around each paint
valve of the ACW mixing unit. The pressure around the base component valve and that around the
hardener valve shall not differ by more than 10%.
(4) Keep the pressure gauge clean enough to ensure clear readings and regularly reduce the pressure
to confirm that the pressure gauge correctly functions.
(5) Use a filter with 100 or more meshes (0.15 x 0.15mm openings) in the paint circuit.

8-10-2 When using a cylinder pump


(1) Install a anti-pulsation device or paint regulator to prevent pulsation due to pump piston changes.
(2) Always use a feeder satisfying requirements of 8-10-1 “When feeding the fluid at a pressure not
higher than 1MPa (for the low-pressure type).”

8-10-3 When using a pressurized (paint) tank


(1) Always install a check valve in the paint circuit to prevent reverse flow.
Different from pumps, the pressurized tank is not equipped to prevent reverse flow of the fluid and
may cause the fluid to circulate between the paint hose and the tank. Always take steps to prevent
reverse flow to the tank.
(2) Provide a safety valve in the tank and a cock valve in the paint circuit for servicing and maintenance.

8-10-4 When using a circulation line


(1) Provide a T-shaped joint in the circulation line to supply to the ACW mixing unit through a single
circuit.
(2) When feeding the paint from the circulation line, always install a cock, paint regulator and paint
pressure gauge at the intake port for servicing and maintenance.

28
9 Hardener Tank (Optional)

WARNING
To prevent danger from toxic substances and compressor
z When working, wear a face mask, safety goggles and protective clothes for protection
against organic solvents.
zAdequately ventilate the workplace so that it will not be filled with a combustible (solvent
containing) atmosphere.

To prevent fire and explosion


zCheck that all units have been correctly grounded.
zAdequately ventilate the workplace so that it will not be filled with a combustible (solvent
containing) atmosphere.

9-1 Hardener tank


To prevent the hardener from hardening in the pump or valves as a result of contact with the moisture in
the air, it must be contained in an enclosed stainless steel tank capable of sealing in nitrogen gas.
(1) Use a Teflon hose to connect the pump and tank.
(2) Adjust the nitrogen gas pressure supplied to the enclosed stainless steel tank between 0.01 and
0.02MPa.
(3) Set the safety valve activating pressure between 0.1 and 0.15MPa.
(4) To check for gas leak, fill the tank with nitrogen gas (0.01 to 0.02MPa), shut off the valve at the supply
side and leave the tank in this state for 2 hours. If the pressure drops to about 3/4 of the initial
pressure, the tank must be leaking. Clean the packing at the filler port, etc. and replace if damaged.
(5) Before starting the coating work, never fail to make sure that the tank contains a sufficient quantity of
hardener for use in the coating work. When the hardener runs short and air is sucked into the tank, an
alarm such as “Hardener Flow Too Low” or “Hardener Flow Too High” is raised. Under certain
circumferences, hardened wastes accumulated in the hardener circuit flow into the flow meters and
valves in the mixing unit, resulting in a disorder or malfunction.
(6) An optional level sensor may be installed in the enclosed stainless steel tank to detect the fluid level at
the lower limit. When installing an intrinsically safe, explosion-proof lower limit level sensor, also
install a separate device to control the sensor.
See 10-4 “Supply of hardener.”

WARNING

There is a possibility of machine disorder, malfunction or hardening in the mid-line.


z If nitrogen gas (N2 gas) leaks from the enclosed stainless tank, the nitrogen gas bomb
becomes empty within only a day. This condition is equivalent to that of a tank with the air
in it not replaced with nitrogen and generates crystal dust and hardened wastes, resulting in
a machine disorder. Regularly check for leak and nitrogen gas pressure drops and repair

29
the tank if leaking.
9-2 Flushing the hardener tank

CAUTION
There is a possibility of machine disorder, malfunction or hardening in the mid-line.
z Do not use any lacquer or alcohol based solution for flushing the equipment. It reacts with
the hardener and accumulates in the flow meters and mixing valves in the equipment and on
inside surfaces of paint hoses just like cholesterol to cause a machine disorder and gel the
fluid in circuits. Always use an exclusive flushing fluid recommended by the paint
manufacturer.

(1) Completely close the main valve of the nitrogen gas bomb and, then, close the pressure reducing valve
of the bomb.
(2) Close the nitrogen gas supply valve at the top of the enclosed stainless steel tank and open the
exhaust valve to release the nitrogen gas until the tank internal pressure becomes 0MPa.
(3) Run the pump connected to the tank to drain the hardener remaining in the tank through the return or
drain circuit of the pump.
(4) Fill the enclosed stainless steel tank with flushing fluid using the attached funnel or such. Wash the
inside of the tank using a brush if necessary.
(5) Let the pump suck the flushing fluid and circulate it for a while.
(6) Drain the flushing fluid through the return or drain circuit of the pump to empty the tank.
(7) The tank can be more effectively cleaned by filling the tank with new flushing fluid and letting the pump
suck and circulate the flushing fluid again.
(8) Overhaul and clean the paint filter, Y-shaped strainer and other filters.
(9) When the equipment is to be withdrawn from service (for about a week), supply new flushing fluid into
the tank to fill the pump and circuit with the flushing fluid. At this time, it is not necessary to supply
nitrogen gas.

30
10 Preparation of Paint and Compressed Air

WARNING
To prevent danger from toxic substances and compressor
z When working, wear a face mask, safety goggles and protective clothes for protection
against organic solvents.
Isocyanate, a chemical agent used as hardener, may hurt mucous membranes in your nose
or throat. Wear a face mask for protection from organic solvents during the work.
Additional protective devices may be required depending on the paint components or
ventilation level. Contact the paint manufacturer.
z Adequately ventilate the workplace so that it will not be filled with a combustible (solvent
containing) atmosphere.

To prevent fire and explosion


z Check that all units have been correctly grounded.
z Adequately ventilate the workplace so that it will not be filled with a combustible (solvent
containing) atmosphere.

10-1 Hoses
(1) Check each hose throughout its length for scars, leak, wear, swells, cracks and loose fittings. In any
of them is found, replace the hose with a new one and restore the equipment to the normal state before
use.
(2) Check hose connectors and joints (especially at the gun mounting section) for loose fittings and fluid
leak. If any leak is found, tighten or replace them.

10-2 Compressed air supply


(1) Use compressed air at 0.4MPa or higher.
(2) The compressed air to be supplied shall be adjustable in pressure and free of oils and debris.
(3) Prepare for air consumption enough to satisfy the spray gun specifications.
(4) If the air pressure at the gun head is too low, change the air hose to the next larger size to reduce the
pressure loss.

10-3 Base component supply


(1) Drain the flushing fluid remaining in the base component can or container and fill it with new paint (base
component).
(2) Run the pump to suck the paint.
(3) Adjust the fluid pressure using the base component regulator so that the base component and
hardener pressures will be the same. For the high-pressure type, the base component pressure shall
be about 10% lower than the hardener pressure.

31
10-4 Hardener supply
(1) Run the pump to drain the flushing fluid remaining in the enclosed stainless steel tank through the
return or drain circuit of the pump.
(2) Fill the tank with hardener using the attached funnel or such with care not to let the hardener stick
around the filler port of the tank or to the O ring (gasket). Wipe off the sticking hardener, if any, with a
waste cloth damped with flushing fluid.
(3) When filling the tank, watch the floating ball in the level gauge provided at the side of the tank not to
overflow the hardener.
(4) Pouring too much hardener through the funnel at a time may lead to an overflow as the opening in the
funnel is small.
(5) Firmly close the tank lid.
(6) Open the main valve of the nitrogen gas bomb and, then, slightly open the pressure reducing valve of
the bomb.
(7) Shut off the exhaust valve at the top of the tank. Then, open the nitrogen gas supply valve to supply
nitrogen gas and adjust its pressure between 0.01 and 0.02MPa. Open the exhaust valve to release
the air from the tank and shut off again 10 seconds later to replace the air with nitrogen gas.
(8) Run the hardener pump to suck the hardener. Operate the pump according to the instruction manual
for pump (feeder).
(9) Adjust the hardener pressure using the paint regulator so that the base component and hardener
pressures will be the same. For the high-pressure type, the hardener pressure shall be about 10%
higher than the base component pressure.
(10) When using a cylinder pump (high-pressure type), fill the cup of the material cylinder with packing
protective agent. Check that the mixing valve and the Teflon tube at the side of the hardener regulator
have also been filled with packing protective agent.
See 9 “Hardener Tank (Optional).”

32
11 ACW Controller

11-1 Description of keys and indicators


11-1-1 Layout of display

1 14

2 13

12
3

4
11

7 8 9 10

11-1-2 Detailed description

1 LCD monitor

NEXT PAGE Scrolls to the next item on the LCD monitor.

PREV. PAGE Scrolls to the previous item on the LCD monitor.

ENTER Used to specify the value to be changed on the LCD monitor.

Used to change a value. Press SKIP and U or V at the same time to quickly change the
SKIP
value. (Note: This key is only effective for some settings.)

UV Used to change a value on the LCD monitor.

2 Valve operation status indicator

AIR PURGE Lights when the air purging valve is on.

THINNER Lights when the thinner valve is on.

Lights when the drain valve is on.


DRAIN (Note: The drain valve has been initially programmed to open for forced flushing after the “Pot
Life Time Up” error. It does not open for normal flushing.)
See 12-5 “Forced flushing after “Pot Life Time Up” error (flushing by automatic control).”

33
3 Mixture ratio indicator

Press this key with the system filled with two-component paint to make the
SETUP
setting changeable.
"SETTING" Indicates the current mixture ratio setting.
"ACTUAL" Indicates the actual mixture ratio.

4 Base component indicator

x Lights when the base component is fed.


"A VALVE"
x The lamp turns on/off according to the input with the spray gun trigger.

LEARN A key for starting “learning.” See 14-4 “Learning.”

"SETTING" Indicates the quantity of base component to be fed.

"ACTUAL" Indicates the quantity of base component actually fed.

5 Hardener indicators

x Lights when the hardener is fed.


"B VALVE"
x The lamp turns on/off according to the input with the spray gun trigger.

LEARN A key for starting “learning.” See 14-4 “Learning.”

"SETTING" Indicates the quantity of hardener to be fed.

"ACTUAL" Indicates the quantity of hardener actually fed.

6 Mode indicator
Lights when the system is filled with two-component paint.
“2K” Blinks during the filling cycle for replacing the flushing fluid with the
two-component paint.

Lights when the flushing process is completed.


“W”
Blinks during the process.

7 Trigger signal indicator

x Lights when the spray gun trigger is pulled (the atomization air is sprayed).
x The “A VALVE” and “B VALVE” lamps turn on/off according to the input with the spray gun
trigger.

34
8 Operation status indicator

x Lights when the READY switch on the local operation panel (optional) is “OFF.” Does not
turn on/off when the local operation panel is not used.
"UNIT"
x When this lamp is lit and the READY switch on, the mode can be changed.
x When this lamp is lit and the READY switch off, the settings can be changed.

x Lights when the READY switch on the local operation panel (optional) is “ON.”
"RMT"
x When this lamp is lit, the mode and settings cannot be changed on the ACW controller.

9 Flow meter indicator

x Indicates the flow per minute during continuous spray.


"FLOW METER" x The indication is updated every cycle (every change from hardener → base component
supply).

10 Buzzer stop and reset keys

BZ. STOP A key for stopping the buzzer in case of an error or alarm.

A key for clearing the error or alarm indication.


RESET (Note: Locate the cause of error or alarm and take necessary action before clearing.)
See 15 “Troubleshooting.”

11 Mode selector
x A key for filling the system with the two-component paint.
Press to replace the flushing fluid with the two-component paint.
“"2K"
x Not effective when the system has been filled with the two-component
paint.
x A key for starting the flushing process.
"W"
x This key can be pressed any number of times.

x Press after flushing with the atomization air supply to the spray gun off to
fill the mixture circuit with solvent.
"SOLVENT"
x A key that becomes effective after flushing and opens the thinner valve
and fills the system with solvent while pressed.

35
12 Function selector

x A key for making the equipment ready for operation.


READY
x The left top lamp lights during the READY mode.

x A key for starting the “mixture ratio test” function (optional).


TEST
x The left top lamp lights during the mixture ratio test.

13 Printer controller (optional function)

REPORT x Prints the quantities of base component and hardener consumed for each two-component
filling process or when any error or alarm occurs and a record of past errors and alarms.
x The left top lamp lights while the data is sent to the printer unit.

START x A key for recording the necessary quantities at any time.


x Press the key to start recording.

STOP A key for printing the data recorded with START.

It is necessary to connect the optional printer before using those keys.

14 Status indicator

POT LIFE Indicates the remaining time of the pot life.

ERROR Lights with a warning sound when an error occurs.


(Error) See 15 “Troubleshooting.”

ALARM 1 Lights with a warning sound when an alarm occurs.


(Alarm) See 15 “Troubleshooting.”
ALARM 2
(Error signal from Not used.
outside)
CHANGING
(Filling/flushing in Lights during the two-component filling or flushing process.
process)
Lights during the two-component filling process.
LOADING Lights during thinner filling process after flushing. (Effective when any input of setting value
(Filling in process) has been made.)
See 7. “Thinner filling time after flushing” of 12-2 “General settings”

36
11-2 Liquid crystal display (screen map)
11-2-1 Ordinary screens

Main title screen


RESET
ACW-1200RUN Ver *.* READY off

SETUP for mixture ratio


I/O monitor
NEXT
PAGE <<<<<< I/O monitor >>>>>>
XXXXXXXXXXXXXXXXXXXX
Mixture ratio
NEXT Paint consumption counter Mix Ratio
PAGE XX.XX
<<Total paint>>
XXXXXXXXXXXXXXXXXXXX
NEXT Mixture ratio set or no input for 30 seconds
PAGE Error and alarm monitor

<<Non Errors>>

READY off
NEXT
PAGE

NEXT
Mixture ratio

Mix Ratio
XX.XX
1
1 *1

PAGE Paint curing time

Pot Life
XX hr XX min
NEXT
PAGE [A] flow correction factor

[A] Correct Pulse r


X. XXX
NEXT
PAGE [B] flow correction factor

[B] Correct Pulse


X. XXX
NEXT
PAGE Air purging time, thinner purging time and number of times

[A] Purge Seq.


XX. X XX. X XX XX. X

NEXT Air purging time before/after flushing


PAGE
First Air Purge W 2K
XX. X XX. X

NEXT
PAGE Thinner filling time after flushing

Thinner filling time


XXX

NEXT
PAGE Drain valve opening time

Drain opening time


X. Xsec
NEXT
PAGE Password

Password
NEXT XXXX
PAGE

37
11-2-2 Password screen (0001)
Password
Password ENTER [A] Flow/Pulse
0001 Base component flow per pulse
X. XXXX ml/pls

NEXT
PAGE
[B] Flow/Pulse Hardener flow per pulse
X. XXXX ml/pls
NEXT
PAGE

Auto Trigger in Flushing


Trigger interlock for flushing/filling
X (0: off, 1: on)
NEXT
PAGE

Alarm Lamp Pattern


Error lamp status in case of error
X (0: light, 1: blink)

NEXT
PAGE

ACW-1200 RUN Ver *.* Main title screen

11-2-3 Password screen (0002)

Password See 14-4 “Learning.”


Password ENTER [B] on to pulse input delay Hardener pulse input time
0002 XXX msec
NEXT
PAGE

[A] off to pulse stop Base component pulse


XXX msec stop time
NEXT
PAGE

[B] off to pulse stop Length of time from turning-off


XXX msec of hardener valve to pulse stop
NEXT
PAGE

4-pulse width in learning t4p_1 for determination of Tm


XXX msec (determined at the time of
learning)
NEXT
PAGE

Pulse number in learning Pulse number (0.5/1.0/2.0) in


XXX XXX XXX pulse learning
NEXT
PAGE

ACW-1200 RUN Ver *.* Main title screen

11-2-4 Password screen (0003)

Password
Password
0003 ENTER Communication station No. Set communication station No.
XX
NEXT
PAGE
Automatic log function Set log mode.
X (0: Ineffective, 1: Effective)
NEXT
PAGE

Clear log information Clear log information.


(Skip) + “ENTER”
NEXT
PAGE

Set clock: (Skip) + “ENTER” Set clock.


2000 / 01 / 01 00:00
NEXT
PAGE

ACW-1200 RUN Ver *.* Main title screen

38
11-2-5 Password screen (0004)

Password See 14-4 “Learning.”


Password ENTER Learning mode
0004 Learning permitting screen
Learning permitted

NEXT
PAGE

ACW-1200 RUN Ver *.*


Main title screen

11-2-6 Password screen (0101) Initialization into the high-pressure mode

Password
Password ENTER High-press. mode ENTER: Initializes. Screen of initialization into
0101 NEXT PAGE: Cancels. the high pressure mode

NEXT
PAGE/ENTER

ACW-1200 RUN Ver *.*

Main title screen

11-2-7 Password screen (0102) Initialization into the low-pressure mode

Password

Password ENTER
0102 Low-press. mode ENTER: Initializes. Screen of initialization into
NEXT PAGE: Cancels. the low pressure mode
NEXT
PAGE/ENTER

ACW-1200 RUN Ver *.*


Main title screen

11-2-8 Paint consumption counter screen

*1

Total Paint
A (A) XXXXXXXXXX ml

Total Paint NEXT ACW-1200 RUN Ver *.*


VU B (1) XXXXXXXXXX ml PAGE

39
12 Parameters

For accurate control of mixing and other functions, set parameters or adjust its values according to the
relevant specifications.
Never fail to note the settings and keep the note with care. See 21 “Settings Recording Sheet.”

NOTE
zIn the case of the high-pressure type, first call the password screen and key in the password <0101>,
then press ENTER . The flushing sequence and flow meter settings are initialized into the
high-pressure mode, preventing erroneous entries.

CAUTION
This is a possibility of malfunction.
Accurate mixing and error detection cannot be ensured without correctly setting parameters.

12-1 Monitors
The monitors are used to check the ACW controller signal status, paint consumption, error/alarm
indications, etc.

(1) I/O monitor


Indicates the on/off status of each I/O.
Description

Used to check the status of input signals from the local operation panel and output signals to the solenoid
valves.

To call: NEXT PAGE To go to another I/O port: U V


Setting

Indication on liquid <<<<<< I/O monitor >>>>>>


crystal display XXXXXXXXXXXXXXX
Remark

See 20 “Assignment of I/Os.”

(2) Paint consumption counter


Description

Indicates the consumed quantities of base component and hardener and total operation time.
To clear: Press U and SKIP at the same time.

To call: NEXT PAGE To check another item: U V


Setting

Indication on liquid <<Total paint>>


crystal display XXXXXXXXXXXXXXXXXX
Remark

40
(3) Error and alarm monitor
Description

Indicates the occurrence of each error.


Press the RESET key to clear the indication.

To call: NEXT PAGE


Setting

Indication on liquid <<Non Errors>>


crystal display XXXXXXXXXXXXXXXXXX
Remark

See 15 “Troubleshooting.”

12-2 General settings


Settings of the following parameters should be changed according to the daily coating operation.
They may be checked or changed with the READY switch on the ACW controller off.

(1) Mix Ratio


Description

The mixture ratio can be specified.


* The mixture ratio can be changed on this screen during the flushing process.

To call: NEXT PAGE To change value: U V (Press U or V with SKIP held down.)
Setting

Changeable range
Indication on liquid Mix Ratio 1.00 to 30.00
crystal display 1.00

Necessity of setting
Remark

See 14-6 “Changing the mixture ratio.” change


€

(2) Usable life (pot life)


If the spray suspension time exceeds the specified time (pot life), a warning is given by the buzzer and
Description

patrol lamp (red).


The drain valve opens 10 minutes after that to forcedly flush the paint circuits from the two component
valves through the drain valve. (Note: The paint circuit downstream the drain valve is not flushed.)
To call: NEXT PAGE To change value: U V
To switch between hour and minute: ENTER
Changeable range
Setting

Pot Life 0 hr 0 min to


Indication on liquid 23 hr 59 min
crystal display
1 hr 00 min
Remark

See 12-5 “Forced flushing after “Pot Life Time Up” error (flushing by automatic Necessity of setting
change
control).” €

x The necessity of setting change is indicated by symbols.


€: To be always changed according to the specifications.
c: To be changed according to the purpose of use.
×: Not to be changed except in special cases.

41
(3) Correction factor for base component flow meter
Description

Key in the flow meter calibration factor relative to the base component viscosity as “correction factor.”
Determine its value according to the separate correction factor table and viscosity conversion table.

To call: NEXT PAGE To change value: U V (Press U or V with SKIP held


Changeable range
down.)
0.001 to 1.999
Setting

Indication on liquid [A] Correct Pulse Necessity of setting


crystal display 1.000 change
×

(4) Correction factor for hardener flow meter


Description

Key in the flow meter calibration factor relative to the hardener viscosity as “correction factor.” Determine
its value according to the separate correction factor table and viscosity conversion table.

To call: NEXT PAGE To change value: U V (Press U or V with SKIP held


Changeable range
down.)
0.001 to 1.999
Setting

Indication on liquid [B] Correct Pulse Necessity of setting


crystal display 1.000 change
×

(5) Flushing conditions


Air: Specify the length of air purging time.
Description

Thinner: Specify the length of thinner purging time.


Times: Specify how many times air and thinner purging is to be repeated.
Filling: Specify the length of mixture filling time.
To call: NEXT PAGE To change value: U V (Press U or V with SKIP held
Changeable range
Setting

down.) 0.0 to 99.9 sec


Indication on liquid [A] Purge Seq. 1 to 99 times
crystal display 2.5 1.5 8 15 0 to 999 (optional)
Remarks

*Note: For the high-pressure type, the air purging valve cannot be adjusted. Set Necessity of setting
the value of “Air” to zero. change
Initialize into the high-pressure mode using password <0101>. €

(6) Initial air purging conditions


Description

W: Specify the length of air purging time before the start of flushing cycle.
2K: Specify the length of air purging time before the start of filling.

To call: NEXT PAGE To change value: U V (Press U or V with SKIP held down.) Changeable
Setting

range
Indication on liquid First Air Purge W 2K
0.0 to 99.9 sec
crystal display 15.0 15.0
Remarks

*Note: For the high-pressure type, the air purging valve cannot be adjusted. Set the Necessity of
value of this parameter to zero. setting change
Initialize into the high-pressure mode using password <0101>. €

(7) Thinner filling time after flushing


Description

Specify the length of the time for filling thinner into the circuit after flushing cycle (air, thinner).

To call: NEXT PAGE To change value: U V (Press U or V with SKIP held down.) Changeable
range
Setting

0.0 to 999 sec


Indication on
Thinner filling time
liquid crystal Necessity of
0
display setting change
c

42
(8) Drain valve opening time
Description

Specify when a special flushing cycle is to be used.


The drain valve is not used for normal flushing cycles.

To call: NEXT PAGE To change value: U V (Press U or V with SKIP held


Setting

down.) Changeable range


Indication on liquid Drain time 0.0 to 99.9 sec
crystal display 0.0 sec
Remarks

Necessity of setting
See 12-4 “Flushing/filling timing chart.” change
×

12-3 Parameters protected by passwords


The following parameters are not necessary for the daily coating work and changing their settings may
affect the mixture control. To protect them, determine the four-digit password to make them accessible to
the authorized personnel only.

12-3-1 Password <0001>

(1) Base component flow meter setting


Description

Specify the flow to be counted per pulse by the base component flow meter.

To call: NEXT PAGE To change value: U V (Press U or V with SKIP held


down.) Changeable range
Setting

0.000 to 1.9999
Indication on liquid [A] Flow/Pulse mL/pls
crystal display 0.115 mL/pls
Necessity of setting
Remarks

For the high-pressure type, set to 0.230mL/pulse. change


Initialize into the high-pressure mode using password <0101>. × (€ for
high-pressure type)

(2) Hardener flow meter setting


Description

Specify the flow to be counted per pulse by the hardener flow meter.

To call: NEXT PAGE To change value: U V (Press U or V with SKIP held


down.) Changeable range
Setting

0.000 to 1.9999
Indication on liquid [B] Flow/Pulse mL/pls
crystal display 0.115 mL/pls
Necessity of setting
Remarks

For the high-pressure type, set to 0.230mL/pulse. change


Initialize into the high-pressure mode using password <0101>. × (€ for
high-pressure type)

(3) Trigger interlock setting for flushing/filling


Description

Set this parameter to “1” not to spray the atomization air during the flushing and two-component filling
processes.

To call: NEXT PAGE To change value: U V


Setting

Changeable range
Indication on liquid Auto Trigger in Flushing 0, 1
crystal display 0 (0: off, 1: on)
Remarks

Necessity of setting
With this parameter set to “1,” the monitor control during the flushing process is
change
cancelled. Never fail to check that the gun has been flushed to its end.
c

43
(4) Error lamp status
Description

You may choose to continuously light or blink the error lamp on the control panel.

To call: NEXT PAGE To change value: U V


Setting

Changeable range
Indication on liquid Alarm Lamp Pattern 0, 1
crystal display 1 (0: light, 1: blink)
Remarks

Necessity of setting
When error output signals from the control panel are used for interlocking, set this
change
parameter to “0.”
c

12-3-2 Password <0002>


Settings of the following parameters are automatically updated when a learning operation is performed.
Their settings can only be checked and must not be changed.
(1) Time from turning-on of hardener mixing valve to pulse input
Description

This data represents the responsiveness of the hardener mixing valve.


The length of time spent after the hardener mixing valve turns on and until the flow meter starts
measurement is indicated.

To call: NEXT PAGE


Setting

Changeable range
Indication on liquid [B] on to pulse input delay 1 to 999 msec
crystal display 40 msec
Remarks

If this value increases after delivery, it means that the responsiveness is decreasing. Necessity of setting
It is necessary to service the mixing valve and replace the intrinsically safe solenoid change
valve. ×

(2) Time from turning-off of base component mixing valve to pulse stop
Description

This data represents the responsiveness of the base component mixing valve.
The length of time spent after the base component mixing valve turns off and until the flow meter stops
measurement is indicated.

To call: NEXT PAGE


Setting

Changeable range
Indication on liquid [A] off to pulse stop delay 1 to 999 msec
crystal display 40 msec
Remarks

If this value increases after delivery, it means that the responsiveness is decreasing. Necessity of setting
It is necessary to service the mixing valve and replace the intrinsically safe solenoid change
valve. ×

(3) Time from turning-off of hardener mixing valve to pulse stop


Description

This data represents the responsiveness of the hardener mixing valve.


The length of time spent after the hardener mixing valve turns off and until the flow meter stops
measurement is indicated.
To call: NEXT PAGE
Setting

Changeable range
Indication on liquid [B] off to pulse stop delay 1 to 999 msec
crystal display 40 msec
Remarks

If this value increases after delivery, it means that the responsiveness is decreasing. Necessity of setting
It is necessary to service the mixing valve and replace the intrinsically safe solenoid change
valve. ×

44
(4) Flow rate in learning
Description

The time required to receive four pulse signals from the flow meter during the learning operation. This
represents the flow rate measured during the learning operation.

To call: NEXT PAGE


Setting

Changeable range
Indication on liquid 4-pulse width in learning 1 to 999 msec
crystal display 40 msec
Remarks

Necessity of setting
The value represents the flow rate measured during the learning operation. change
×

(5) Pulse number in learning


Description

Indicates the pulse number counted when the hardener mixing valve is instantly opened and closed.

To call: NEXT PAGE


Setting

Changeable range
Indication on liquid Pulse number in learning 1 to 999 msec
crystal display 0 5 10 pulse
Remarks

Necessity of setting
The instant valve operating conditions are recorded assuming the quick switching of
change
the spray on/off status.
×

12-2-3 Password <0003>


The following parameters are used when the optional printer has been installed.
When it has not been installed, do not set these parameters.
(1) Communication station No.
Description

Two or more ACW controllers can be connected to a single printer and, therefore, the station No. of the
exclusive printer shall be specified.

To call: NEXT PAGE To change value: U V


Setting

Changeable range
Indication on liquid Communication station No. 0 to 15
crystal display 0
Remarks

Necessity of setting
Set to “1” when the printer has been connected. change
×

(2) Clearing the log information


Description

The record (log) information accumulated in the exclusive printer can be cleared.
Press the SKIP and ENTER keys at the same time to reset.

To call: NEXT PAGE


Setting

Indication on liquid Clear log information


crystal display (Skip) + “ENTER”
Remarks

Necessity of key
Once cleared, the information cannot be recovered. operation
×

45
(3) Clock setting
Description

When an exclusive printer is used, it is necessary to set the date and time. Enter the current time and
press the SKIP and ENTER keys at the same time to set and start the clock.

To call: NEXT PAGE To change value: U V


Setting

Indication on liquid Set clock: (Skip) + “ENTER”


crystal display 2000 / 01 / 01 00:00
Remarks

Necessity of key
If the time printed on the paper coming out of the printer is different from the preset
operation
time, set the clock again.
×

12-3-4 Password <0004>


This screen shall be called to the display before performing the learning operation.
(1) Learning mode
Description

Before performing the learning operation, switch to this screen.

To call: NEXT PAGE To change value: U V


Setting

Indication on liquid Learning mode


crystal display Learning permitted
Remarks

Necessity of key
See 14-4 “Learning.” operation
€

12-3-5 Password <0101>


This screen is used to change the basic settings for high-pressure mode back to default values.
(1) High-pressure mode initializing screen
Description

Keying in this password in the high-pressure mode only permits the initialization of basic settings (flushing
parameters and flow meter settings). Setting errors can be prevented by doing this..

To call: NEXT PAGE To change value: U V


Setting

Indication on liquid High-pressure mode ENTER: Initializes.


crystal display NEXT PAGE: Cancels.
Necessity of key
Remarks

Settings of the mixing ratio and pot life are not changed in this operation. See 12-2 operation
“General Settings” for settings for the high-pressure type. × (€ for
high-pressure type)

12-3-6 Password <0102>


This screen is used to change the basic settings for low-pressure mode back to default values.
(1) Low-pressure mode initializing screen
Description

This screen is used to switch the high-pressure mode back to the low-pressure mode. Keying in this
password only permits the initialization of basic settings (flushing parameters and flow meter settings).
Setting errors can be prevented by doing this.
To call: NEXT PAGE To change value: U V Necessity of key
Setting

operation
Indication on liquid Low-pressure mode ENTER: Initializes
×
crystal display NEXT PAGE: Cancels.

46
12-4 Flushing/filling timing charts
12-4-1 Flushing timing chart (for the low-pressure type)

Mode switching total time


Air purging

Thinner filling *1

Drain valve*3 *5
*2
Gun trigger
*4 (trigger off) Valve operation status

*1. The length of initial air purging (W) time. The operation does not start when the setting value is “0.”
*2. The number of times the air purging and thinner flushing are to be repeated. This number can be
changed.
*3. The drain valve only opens when the opening time has been set. See Note below.
*4. Turning off the gun trigger during the flushing operation raises the alarm “Mode Change in Process.”
Keep pulling the trigger. See “WARNING” below.
*5. The length of the time for filling flushing thinner. The operation does not start when the setting value
is “0.”

12-4-2 Flushing timing chart (for the high-pressure type)

Mode switching total time


Air purging *1
*3
Thinner filling
Drain valve*3 *5
Times: 1
Gun trigger
*4 (trigger off) Valve operation status

*1. Set the initial air purging (W) and air purging times to “0.”
*2. Set the thinner flushing time and set the number of times to “1.” (The settings are defaulted for the
high-pressure type and need to be changed).
*3. The drain valve only opens when the opening time has been set. See Note below.
*4. Turning off the gun trigger during the flushing operation raises the alarm “Mode Change in Process.”
Keep pulling the trigger. See “CAUTION” below.
*5. The length of the time for filling flushing thinner. Set the time to “0.”

Notes
z A higher flushing efficiency may be achieved when the drain valve is not used for ordinary
flushing. Set the opening time to “0.”·
zModify the flushing cycle according to the hose length and paint color.

CAUTION
Hardening in the mid-line may occur.
z With the trigger interlock set to “1” (effective) for flushing/filling, the flushing cycle goes on
regardless of the input with the spray gun trigger. In this case, the flushing can be
performed with the atomization air for spray gun off and no warning is given if the trigger is
turned off in the middle. Never fail to check that the flushing has been completely
performed. Failure to keep the tripper pulled throughout the flushing cycle may lead to

47
hardening in the mid-line.

12-4-3 Filling timing chart (for the low-pressure type)


Filling time

Air purging *1

Base component mixing valve

Hardener mixing valve

*2
Gun trigger Valve operation status

*3 (trigger off)

*1. The length of initial air purging time. This is not included in the filling time.

*2. Indicates the initial filling quantity (5ml). Components shall be supplied in units of 5ml for the first
mixing cycle.

*3. Turning off the gun trigger during the filling operation raises the alarm “Mode Change in Process.”
Keep pulling the trigger. See “Notes” below.

12-4-4 Filling timing chart (for the high-pressure type)

Filling time

Air purging *1

Base component mixing valve

Hardener mixing valve

*2
Gun trigger
Valve operation status
*3 (trigger off)

*1. Set the initial air purging time (2K) to zero.

*2. Indicates the initial filling quantity (5ml). Components shall be supplied in units of 5ml for the first
mixing cycle.

*3. Turning off the gun trigger during the filling operation raises the alarm “Mode Change in Process.”
Keep pulling the trigger. See “Notes” below.

Notes
z When the filling time has been set, components are supplied in units of 5ml for the first
mixing cycle regardless of the target quantities specified on the ACW controller (initial filling
function).
zTurning off the trigger before the end of the filling time raises the alarm “Mode Change in
Process.”
zWith the trigger interlock set to “1” (effective) for flushing/filling, the filling cycle goes on
regardless of the input with the spray gun trigger. In this case, the filling can be performed
with the atomization air for spray gun off.

48
12-5 Forced flushing after “Pot Life Time Up” error (flushing by automatic control)
An automatic flushing cycle starts 10 minutes after the pot life counter has counted down to zero. The
ACW mixing unit is forcedly flushed with the compressed air supplied, the ACW1200 control unit
powered on, the flushing pump running and the flushing fluid pressurized.

Notes
The spray gun, mixing hose and paint hose upstream the gun are not flushed at this time

(Fixed to 10 minutes)
Forced flushing started

“Pot Life Time Up” error

The forced flushing is started a specified time after the “Pot Life Time Up” error is raised. No spray signal is required.

A single cycle for 20 seconds (fixed)

Thinner

Drain valve
As the forced flushing is started, the drain valve automatically turns on to drain the mixture in the ACW mixing
unit.

Notes
z The power and compressed air shall be supplied to the ACW1200 control unit and the
flushing pump running before the forced flushing can be performed.
z If the “Pot Life Time Up” error is raised or the forced flushing is performed, the system
cannot be reset without flushing (pressing the W button). If no flushing fluid comes out of
the gun head during the flushing operation, the paint may have been hardened in the mid-line
and it is necessary to overhaul and clean the unit.

CAUTION
Hardening in the mid-line may occur.
z Never fail to flush before the end of pot life. Especially when using a paint with a shorter pot
life, flush the equipment at shorter intervals.
z At the end of flushing operation, always check with eyes that the flushing fluid has come out
of the gun nozzle.

49
13 Preparation for Operation and Cautionary Notes

13-1 Preparation for operation


13-1-1 Power-up procedure and cautionary notes
(1) After connecting the paint and air hoses and cables, supply the paint and compressed air.
See 8 “Unpackaging and Installation” and 10 “Preparation of Paint and Compressed Air.”
(2) Check that the air pressure supplied to the ACW1200 control unit and ACW mixing unit (intrinsically
safe solenoid valves) have been set to zero so that the equipment does not accidentally move.
(3) Turn on the power switch of the ACW1200 control unit. All lamps on the ACW controller light for
about five seconds. Check the lamps for blown bulbs
(4) After the power-up, check that the READY lamp on the ACW controller is off. Also check that the
“ACTUAL” indicators for “A VALVE” and “B VALVE” read 0.00 and do not count up. If they count up,
the exclusive flow meter cable may be affected by noise. Check the grounding.
(5) Supply compressed air to the ACW1200 control unit and ACW mixing unit (intrinsically safe solenoid
valves).
(6) Open the air cock at the side of the ACW1200 control unit to supply compressed air to the spray gun.

WARNING
To prevent danger from misuse of the equipment
z Before the power-up, always reduce the air supply pressure to zero so that the equipment does
not accidentally move.
To prevent fire and explosion
z Before the power-up, check that all units have been correctly grounded.
zBefore the power-up, check for combustible (solvent containing) atmosphere around the
ACW1200 control unit. Do not turn on the power switch in the presence of a combustible
atmosphere even in a small quantity.

13-1-2 Paint conditions


(1) Never fail to adjust the fluid (base component and hardener) pressures using the respective paint
regulators. Adjust the pumps (feeders) to prevent pulsation of the fluid flow and so that the dynamic
(not static) pressures of the base component and hardener will be the same

WARNING
Accurate mixture control may be prevented, resulting in an incorrect mixture
ratio or insufficient flow
z Failure to adjust the paint pressures using the regulators may lead to an incorrect mixture ratio
(poor mixing) or pulsation of the spray. Keep a higher pump pressure and install paint
regulators to prevent pulsation.
(2) Above all, keep a sufficient quantity of flushing fluid in stock. Be prepared to immediately flush the
equipment in case of the “Pot Life Time Up” error or hardening in the spray line. See 7-3 “Flushing fluid.”

50
13-1-3 Setting the parameters
Set the mixture control and flushing/filling timing chart parameters. See 12 “Parameters.”

CAUTION
Accurate mixture control may be prevented. See 14 “Operating Procedures.”
zThe mixture control and “learning” operation cannot be correctly performed without properly
setting the parameters.

13-2 Caution in operation


13-2-1 Mixture in mixing hose
When suspending the spray operation for an extended period or changing the mixture ratio, it is necessary
to discard the mixture in the mixing and paint hoses and spray gun.
<Reference: Hose specifications and waste spray quantities>
Mixing unit Mixing hose, 6mm in Mixing hose Waste spray
ID Hose capacity
capacity ID, 3m long through gun quantity
Hose length φ6mm 85mL 195mL
10mL 100mL
3m φ4mm 40mL 150mL

Calculate the length of waste spray time from the flow rate and waste spray quantity.

13-2-2 Operation of spray gun


(1) This equipment alternately supplies the base component and hardener and may not control the
alternate supply if the spray gun on/off intervals are too short (1 second or less).
(2) Keep pulling the spray gun trigger during the flushing or two-component filling cycle. Releasing the
trigger or stopping the spray in the middle may result in an error or poor control.
(3) Do not blow air using the spray gun (air spray or lap gun). The atomization air for spray gun serves
as a starting switch for mixture control. Blowing air with the spray gun raises the “Flow Too Low”
alarm. In this case, press BZ. STOP 1 and RESET 2 to recover.

13-2-3 Main title screen and operation panel


(1) Do not turn off the READY switch 3 until the daily coating work is finished. Turning on/off the READY
switch 3 resets the feeding process in the middle and restarts the process from the hardener supply to
make some parts overloaded with hardener. In this case, continue the waste spray for a while.
(2) Before starting the work, always check that no error or alarm has been pending.
(3) Keep the ACW controller clean. If contaminated with paint, switch labels may become illegible,
resulting in an operational error.

51
13-3 Regular learning operation

The following operation shall be performed to ensure an accurate mixture control.

Operation Frequency Reference


Learning Every six months 14-4 “Learning”

13-4 To release the mixture pressure


The procedure for releasing the pressure in the paint circuit from the mixing unit to the spray gun for
maintenance of the spray gun or replacement of hoses is described below.

13-4-1 When the local operation panel has not been used
(1) Press the READY key 1 on the ACW Controller to turn off the lamp at the left top of the key.
(2) When an static spray gun has been used, turn off the power switch on the static controller to stop
generation of high voltages.
(3) If the paint regulators, cocks, etc. have been installed in the paint circuit, make them open.
(4) Put the spray gun onto a grounded metal container and pull the trigger to release the pressure.
(5) When releasing the pressure in the circuit after flushing, perform steps (1) to (4) above after changing
the mode to “W.” See 14 “Operating Procedures.”

13-4-2 When the local operation panel has been used


(1) Turn off the READY switch 1 on the local operation panel.
(2) Perform steps (2) to (4) or (5) in the previous paragraph. See 14 “Operating Procedures.”

52
14
14-1 Operation
Operating Procedures

(1) Press the READY key 1 on the ACW Controller to turn on the lamp at the left top of the key.
(2) In the W mode (“W” lamp 2 lit), the lamp 3 lights when the spray gun trigger is pulled. At the same
time, the lamp 4 lights and the thinner supply starts. Releasing the trigger turns off the lamps 3 and 4
and closes the thinner valve to stop the supply. The thinner does not pass through a flow meter and,
therefore, its flow rate 5 and measured quantity 6 are not indicated.
(3) Switch to the 2K mode (“2K” lamp 7 lit) and pull the spray gun trigger. Then, the hardener valve lamp
8 and base component valve lamp 9 alternately light and the flow rate and measured quantity are
indicated. This means that the mixing valves are operating and feeding the mixture. The lamp 3
lights again as the trigger is pulled.

13

9 1

6
4

5
8

10
2

11
3

12

14-2 Mode change from ACW controller


The flushing (W) and two-component filling (2K) modes can be switched from the ACW controller.

WARNING
To prevent danger from toxic substances
z When working, wear a face mask, safety goggles and protective clothes for protection against
organic solvents.
zAdequately ventilate the workplace so that it will not be filled with a combustible (solvent
containing) atmosphere
To prevent fire and explosion
zCheck that all units have been correctly grounded.
zAdequately ventilate the workplace so that it will not be filled with a combustible atmosphere.
To prevent danger from the spray
z Never aim the head of a spray gun to your body or another person or cover the nozzle with
your finger, palm or another part of your body.

53
CAUTION
Hardening in the mid-line may occur.
z If an error or alarm occurs (the buzzer sounds) during the mode change, always check the
content of the error or alarm on the ACW controller display and take the specified action
against it.
z If the equipment cannot be thoroughly flushed, change the flushing parameter settings.

14-2-1 Filling the unit with two-component paint (1) (switching from W to 2K (1))
<When the trigger interlock has been set to “0” (ineffective) for flushing/filling>
(1) Check the pump operation status and the base component and hardener pressures.
(2) Press the READY key 1 on the ACW controller to turn on the lamp at the left top of the key.
(3) Press the 2K key 10 on the ACW controller and pull the trigger.
(4) The “LOADING” lamp 13 lights and the “2K” lamp 7 blinks.
(5) After the filling is finished, the “2K” lamp 7 continuously lights. Releasing the trigger before the lamp
continuously lights raises the alarm “Mode Change in Process.” Keep pulling the trigger until the
lamp continuously lights.

14-2-2 Filling the unit with two-component paint (2) (switching from W to 2K (2))
<When the trigger interlock has been set to “1” (effective) for flushing/filling>
(1) Repeat steps (1) and (2) above
(2) Close the atomization air cock at the bottom of the ACW1200 control unit. Installing the air cock
around the spray gun facilitates the operation.
(3) Press the 2K key 10 on the ACW controller and pull the trigger. At this time, the atomization air is not
sprayed but forces out the thinner in the circuit to fill the circuit with the two-component paint.
(4) The “LOADING” lamp 13 lights and the “2K” lamp 7 blinks.
(5) After the filling is finished, the two-component paint supply automatically stops.
(6) Open the atomization air cock at the bottom of the ACW1200 control unit to start the coating operation.

14-2-3 Flushing (1) (switching from 2K to W (1))


<When the trigger interlock has been set to “0” (ineffective) for flushing/filling>
(1) Check the pump operation status and the remaining flushing fluid quantity and pressure.
(2) Press the READY key 1 on the ACW controller to turn on the lamp at the left top of the key
(3) Press the W key 11 on the ACW controller and pull the trigger.
(4) The “LOADING” and “CHANGING” lamp 13 lights and the “W” lamp 2 blinks.
(5) After the flushing is finished, the “W” lamp 2 continuously lights. Releasing the trigger before the
lamp continuously lights raises the alarm “Mode Change in Process.” Keep pulling the trigger until
the lamp continuously lights.

54
14-2-4 Flushing (2) (switching from 2K to W (2))
<When the trigger interlock has been set to “1” (effective) for flushing/filling>
(1) Repeat steps (1) and (2) above.
(2) Close the atomization air cock at the bottom of the ACW1200 control unit. Installing the air cock
around the spray gun facilitates the operation
(3) Press the W key 11 on the ACW controller and pull the trigger. At this time, the atomization air is not
sprayed but forces out the two-component paint in the circuit for flushing.
(4) The “LOADING” and “CHANGING” lamps 13 light and the “W” lamp 2 blinks.
After the flushing is finished, the atomization air supply automatically stops.
(5) Open the atomization air cock at the bottom of the ACW1200 control unit and pull the trigger to feed
the flushing thinner.

14-3 Mode change from local operation panel


The flushing (W) and two-component filling (2K) modes can be switched from the local operation panel.

1 2

3 4

14-3-1 Filling the unit with two-component paint (1) (switching from W to 2K (1))
<When the trigger interlock has been set to “0” (ineffective) for flushing/filling>
(1) Check the pump operation status and the base component and hardener pressures.
(2) Set the READY switch 1 on the local operation panel to “ON.”
(3) Set the switch 2 on the local operation panel to “2K,” press the “START” button 3 and pull the trigger.
(4) Releasing the trigger before the end of the specified filling time raises the alarm “Mode Change in
Process.” Keep pulling the trigger.

14-3-2 Filling the unit with two-component paint (2) (switching from W to 2K (2))
<When the trigger interlock has been set to “1” (effective) for flushing/filling>
(1) Repeat steps (1) and (2) above.
(2) Close the atomization air cock at the bottom of the ACW1200 control unit. Installing the air cock
around the spray gun facilitates the operation.
(3) Set the switch 2 on the local operation panel to “2K,” press the “START” button 3 and pull the trigger.
At this time, the atomization air is not sprayed but forces out the thinner in the circuit to fill the circuit
with the two-component paint.
(4) After the filling is finished, the two-component paint supply automatically stops.
(5) Open the atomization air cock at the bottom of the ACW1200 control unit to start the coating operation.

55
14-3-3 Flushing (1) (switching from 2K to W (1))
<When the trigger interlock has been set to “0” (ineffective) for flushing/filling>
(1) Check the pump operation status and the remaining flushing fluid quantity and pressure.
(2) Set the READY switch 1 on the local operation panel to “ON.”
(3) Set the switch 2 on the local operation panel to “W,” press the “START” button 3 and pull the trigger.
(4) Releasing the trigger before the end of the specified filling time raises the alarm “Mode Change in
Process.” Keep pulling the trigger.

14-3-4 Flushing (2) (switching from 2K to W (2))


<When the trigger interlock has been set to “1” (effective) for flushing/filling>
(1) Repeat steps (1) and (2) above.
(2) Close the atomization air cock at the bottom of the ACW1200 control unit. Installing the air cock
around the spray gun facilitates the operation.
(3) Set the switch 2 on the local operation panel to “W,” press the “START” button 3 and pull the trigger.
At this time, the atomization air is not sprayed but forces out the two-component paint in the circuit for
flushing.
(4) After the flushing is finished, the atomization air supply automatically stops.
(5) Open the atomization air cock at the bottom of the ACW1200 control unit and pull the trigger to start
supplying the flushing thinner.

56
14-4 Learning
This is intended to determine the mixing valve opening/closing timings according to the actual flow rate.
When the flow rate is significantly changed (to more than twice the initial level), the learning operation
shall be performed to let the system recognize the opening/closing timings again. The learning operation
shall also be performed to let the system recognize the valve response timings again when system has
been operated for about six months.

WARNING
To prevent danger from toxic substances
z When working, wear a face mask, safety goggles and protective clothes for protection against
organic solvents.
z Adequately ventilate the workplace so that it will not be filled with a combustible (solvent
containing) atmosphere.
To prevent fire and explosion
z Check that all units have been correctly grounded.
z Adequately ventilate the workplace so that it will not be filled with a combustible atmosphere.
To prevent danger from the spray
z Never aim the head of a spray gun to your body or another person or cover the nozzle with
your finger, palm or another part of your body.

14-4-1 Learning procedure


(1) Fill the system with the two-component paint.
(2) Open the learning screen using password <0004> on the liquid crystal display. See 11-2-5 “Password
screen (0004).”
(3) Press the LEARN key 1 for base component or hardener to light both lamps. (Pressing either key
lights lamps on both keys.)
(4) Press the READY key 2
(5) Continue spraying until the lamp on the LEARN key 1 turns off. (Do not stop spraying in the middle.
Doing so raises the alarm “Flushing/Learning in Process.”
(6) Never fail to note the settings after learning. Open the parameter screens using password <0002> on
the liquid crystal display and note the settings. See 11-2-3 “Password screen (0002)” and 21
“Settings Recording Sheet.”

CAUTION
Accurate mixture control may be prevented.
z The valve responsiveness is measured and the mixture ratio is not maintained during the
learning process. The mixture ratio errors are not detected at this time. Do not perform the
coating operation during the learning process.
z Stopping spraying in the middle of the learning process raises the alarm “Flushing/Learning in
Process.” Do not stop spraying in the middle.

57
14-5 Mixture ratio test (optional)

14-5-1 Mixture ratio test


This is performed to check the mixture ratio. When performing the mixture ratio test, it is necessary to
change the mixing unit with the following product.

Part No. 4436 Part name Metering unit


The unit shall be replaced by changing the mixing block body. See 16-3 “Mixing block.”

14-5-2 Procedure for mixture ratio test (optional)


Accurate test results may not be obtained when the actual flow rates are significantly different from the
flow rates used for the mixture ratio test. Never fail to adjust the flow rates during the test.

WARNING
To prevent danger from toxic substances and compressor
zWhen working, wear a face mask, safety goggles and protective clothes for protection against
organic solvents.
zAdequately ventilate the workplace so that it will not be filled with a combustible (solvent
containing) atmosphere.

(1) Prepare the following tools for use in the mixture ratio test.
Tool used Description

1 Two cups with a capacity about 300ml Used for adjusting the flow rate.
Two cups with a known weight and a The cups shall be weighed in advance so that the components can be
2
capacity about 300ml accurately weighed with a precision scale in determining the mixture ratio.
Used for weighing the paint. The scale shall be capable of weighing to each
3 Electronic scale
0.1g and up to 1kg.
(2) Fill the system with the two-component paint.
(3) Note the flow rates during the spraying operation.
(4) Put the Teflon tubes for base component and hardener 1 in the cups prepared for adjustment and
open the metering valves 2.
(5) Pull the spray gun trigger to spray the atomization air only. The base component and hardener come
out of the Teflon tubes.
(6) Adjust the metering valves to approximately obtain the noted flow rates while checking the flow rates
indicated on the display.
(7) Release the spray gun trigger to stop the atomization air and feeding through from the Teflon tubes.
(8) Put the Teflon tubes for base component and hardener in the measuring cups and press the TEST key
on the ACW1200 controller. The base component and hardener are alternately fed five times.

Notes
An excessive fluid velocity leads to larger measuring errors while an insufficient fluid velocity
raises the “Flow Too Low” alarm. Adjust the metering valves to obtain the flow rates almost
equivalent to the actual levels.

(9) Weigh the base component and hardener using a scale and calculate the mixture ratio (by volume)
and the difference from the actual mixture ratio.
See 7-4 “Ratio by weight and ratio by volume.”
(10) If the difference is too large, repeat the learning operation. Check the flow meters for wrong settings.
See steps (1) and (2) of 12-3-1 Password <0001>.
(11)Then, close the metering values.

58
(12)Press W (WASH) to flush the whole circuit through the spray gun.
(13)At last, flush the metering valves 2 and Teflon tubes 1 by flowing the flushing fluid. At this time, open
the metering valves and pull the spray gun trigger to drain the flushing fluid through the Teflon tubes.
Receive the flushing fluid drained through the Teflon tubes into an appropriate container.

Notes
z Never fail to adjust the metering valves to approximately obtain the noted flow rates. If the
flow rates during the actual spraying operation and those used for the test are different, the
mixture ratio cannot be accurately measured.
z Calculate the mixing ratio by volume.
z If the base component and hardener viscosities are not within the specified limits, accurate
measurements cannot be obtained.

A 2
<Part No. 4436>
1

Overhaul the mixing block and replace part A as


shown above. See 16 “Breakdown Drawings.”
14-6 Changing the mixture ratio
14-6-1 When changing with the system filled with two-component paint
(1) Press the READY key 1 on the ACW Controller to turn off the lamp at the left top of the key.
(2) Press the ENTER key 2 to turn on the lamp at the left top of the key.
(3) Change the mixture ratio by pressing U or V or pressing SKIP and U or V at the same time.
(4) Press the ENTER key 2 to turn off the lamp at the left top of the key. See 12 “Parameters.”
14-6-2 When setting in the flushing mode
(1) Press the READY key 1 on the ACW Controller to turn off the lamp at the left top of the key.
(2) Keep pressing the NEXT PAGE key 3 until the LCD reads Mixture Ratio.
(3) Key in the mixture ratio specified by the paint manufacturer s document (by weight) by pressing U
or V or pressing SKIP and U or V at the same time.

3 1

59
15 Troubleshooting
The procedure for switching screens, causes of errors and alarms and how to correct them are described
herein. If any error or alarm occurs, stop working, locate the cause and take corrective action before
restarting the coating operation.

15-1 If any error or alarm occurs


If any error or alarm occurs, it is indicated by a buzzer and (red) lamp.
The ACW controller shows the content of the error or alarm on the liquid crystal display. The “ERROR”
or “ALARM1” lamp lights depending on which has occurred.
Press BZ. STOP to stop the buzzer.
Press RESET to clear the error or alarm indication on the liquid crystal display and turn off the “ERROR”
or “ALARM1” lamp and the red lamp.

Indicator lamps (Red) lamp

Buzzer

Liquid crystal
display

ACW controller ACW1200 control unit

15-2 List of errors and alarms


INDICATION ON DISPLAY CONTENT OF ERROR OR ALARM

Pot Life Time Up Forced flushing to be started


Ratio Error A wrong mixing ratio
Errors

Insufficient base component flow rate (applicable to Ver.


Flow [A] Too Low
2.02 and successors)
Insufficient hardener flow rate (applicable to Ver. 2.02
Flow [B] Too Low
and successors)
Do Flush (Press W) End of pot life reached
Insufficient base component flow rate (applicable to Ver.
Flow [A] Too Low
2.01)
Flow [B] Too Low Insufficient hardener flow rate (applicable to Ver. 2.01)
Flow [A] at Stopped Base component valve leaking
Alarms

Flow [B] at Stopped Hardener valve leaking


Mode Change in Process Mode being changed
Test/Learn in Process Learning or mixture ratio test (optional) being performed
Flow [A] Too High Excessive base component flow rate
Flow [B] Too High Excessive hardener flow rate
Parameters Not Set RAM initialized

60
15-3 Errors
The “error” means an indication by the buzzer and (red) lamp that any of the troubles listed below has
occurred to turn off READY switch and suspend the control functions. The content of the trouble is
indicated on the liquid crystal display.

15-3-1 How to clear the error indication


The error indication can be cleared by pressing the RESET button on the ACW controller. If poor
operation or incorrect pump motion results from wear of a component of the mixing unit or there is electric
noise, the same error will be indicated again after pressing RESET. Locate the cause and take
necessary action such as repair of faulty parts or removal of electric noise before restarting the coating
operation.
The “Pot Life Time Up” error cannot be reset by pressing RESET.

15-3-2 Detail of errors


(1) Pot Life Time Up
Description

Indicated when the forced flushing is started 10 minutes after the end of pot life is reached. See 12-5
“Forced flushing after “Pot Life Time Up” error.”
Indication

Pot Life Time Up


To clear

Press W and finish flushing to clear. Cannot be cleared by pressing RESET. Supply an adequate quantity
of flushing fluid (thinner) into the flushing pump and press W to flush.
Cause

The equipment was not flushed by the operator’s input at the end of pot life and the forced flushing was
started 10 minutes after that.
Remedy

Flush the mixing unit when it is not to be used for a while.

(2) Ratio Error


Description

Indicated when the mixture ratio of base component and hardener exceeds the specified limit.
All functions are stopped and the READY switch turned off.
Indication

Ratio Error
To clear

After locating the cause and taking preventive action, press RESET to clear the error indication. Then, set
the READY switch to “ON” to start the coating operation.

(1) A malfunction of the base component or hardener valve


(2) A malfunction of the intrinsically safe explosion-proof solenoid valve for base component or hardener
Cause

mixing valve
(3) Excessive flow rate variations
(4) Flow rate at the time of filling next color is far higher than that at the time of normal spraying.
(1) Replace consumable parts of the base component or hardener valve.*Note: When assembling, make sure
to fill a packing protective solution. <Part No., 3979-1>
(2) Check the pilot air tube. Replace the intrinsically safe explosion-proof solenoid valves with new ones.
Remedy

(3) Reduce the flow rate variations. When two or more guns are used, let the system “learn” at the mean flow
rate between the maximum and minimum. See 14-4 “Learning”
(4) Control the fluid velocity during the two-component filling process. If the flow rate is abruptly reduced
after filling the system, the same trouble will occur. The flow rate shall be slowly reduced.

61
15-4 Alarms
The “alarm” means an indication by the buzzer and (red) lamp that any of the troubles listed below has
occurred. The content of the trouble is indicated on the liquid crystal display. If any alarm occurs, the
mixture continues to work.

15-4-1 How to clear the alarm indication


The alarm indication can be cleared by pressing the RESET button on the ACW controller. If poor
operation or incorrect pump motion results from wear of a component of the mixing unit or there is electric
noise, the same alarm will be indicated again after pressing RESET. Locate the cause and take
necessary action such as repair of faulty parts or removal of electric noise before restarting the coating
operation.

15-4-2 Detail of alarms


(1) Do Flush
Description

Indicated when the pot life counter reads zero. The pot life is not counted down while the system stays in the
flushing mode (“W” lamp lit).See 12-5 “Forced flushing after “Pot Life Time Up” error (flushing by automatic
control).”
To clear Indication

Do Flush (Press W)

Press W and finish flushing to clear. Cannot be cleared by pressing RESET. Supply an adequate quantity
of flushing fluid (thinner) into the flushing pump and press W to flush.
Cause

(1) The pot life is over.


(2) The preset length of pot life is too short.
Remedy

(1) Flush the unit when suspending the coating operation for a while.
(2) Increase the preset length of pot life. See 12-2 General settings.

(2) Base Component Flow Too Low


ACW1200 controller ver. 2.02 and successors determine this condition as an “Error”; turn OFF the READY
to suspend the control.
Description

Indicated when the flow rate drops below 20mL/min (fixed limit) during the base component supply.
Indication

Flow [A] Too Low


To clear

After locating the cause and taking preventive action, press RESET to clear the alarm indication. Then, turn
ON the READY to resume the coating operation.
(1) Clogging matter or hardening in the nozzle or paint regulators
(2) Clogging paint or foreign matter between gears in flow meters
(3) Flow meter cables are affected by noise.
Cause

(4) Clogging matter or cured paint in check valves


(5) A malfunction of the base component mixing valve
(6) Clogging matter or hardening in the mixing hose, static mixer or paint hose
(7) Disorder of or air leak from the intrinsically safe explosion-proof solenoid valve
(1) Remove nozzle clogging matter and overhaul and clean the paint regulators.
(2) Overhaul and clean flow meters.
(3) Check the shield earths of cables. Change the shield earth grounding method.
Remedy

(4) Overhaul and clean the check valves.


(5) Check the pilot air tube. Overhaul and clean the base component mixing valve and replace consumable parts.
*Note: When assembling, make sure to fill a packing protective solution. <Part No. 3979-1>
(6) Overhaul and clean the static mixer. Replace the paint hoses.
(7) Replace the intrinsically safe explosion-proof solenoid valves.

62
(3) Hardener Flow Too Low
ACW1200 controller ver. 2.02 and successors determined this condition as an “Error”; turn OFF the READY
to suspend the control.
Description

Indicated when the flow rate drops below 20mL/min (fixed limit) during the hardener supply.
To clear Indication

Flow [B] Too Low

After locating the cause and taking preventive action, press RESET to clear the alarm indication. Then, turn
ON the READY to resume the coating operation.
Cause

(1) A malfunction of the hardener mixing valve


(2) For other causes, see “Base Component Too Low.”
Remedy

(1) Check the pilot air tube. Overhaul and clean the hardener mixing valve and replace consumable parts.
(2) For other remedies, see “Base Component Flow Too Low.”

(4) Base Component Flow When Stopped


Description

Indicated when pulses are issued by the base component flow meter (the “ACTUAL” value is updated) during
suspension of the mixture control or with the base component valve closed.
To clear Indication

Flow [A] at Stopped

After locating the cause and taking preventive action, press RESET to clear the alarm indication. Then,
restart the coating operation.
(1) The learning was not correctly performed (the valve response timing is wrong).
(2) A malfunction of the base component mixing valve
(3) Disorder of or air leak from the intrinsically safe explosion-proof solenoid valve
Cause

(4) The flow meter body is affected by noise (flow meter and sensor connection is loose).
(5) The flow meter cable is affected by noise from a high tension (200VAC) cable or such.
(6) Corona discharge from the static gun is acting as noise.
(7) A robot has been installed near the mixing unit.
(1) Perform the learning operation again. See 14-4 “Learning.”
(2) Check the pilot air tube. Overhaul and clean the base component mixing valve and replace
consumable parts.
*Note: When assembling, make sure to fill a packing protective solution. <Part No. 3979-1>
Remedy

(3) Check the pilot air tube. Replace the intrinsically safe explosion-proof solenoid valve with a new one.
(4) Ground the flow meter body and shielded wire of the flow meter cable.
(5) Modify to avoid crossing with another cable.
(6) Modify the routing so that the static gun will not draw near (within 1m of) the mixing unit. If it inevitably
draws near the mixing unit, turn off the static gun.
(7) Correctly ground the ACW mixing unit.

63
(5) Hardener Flow When Stopped
Description
Indicated when pulses are issued by the hardener flow meter (the “ACTUAL” value is updated) during
suspension of the mixture control or with the hardener valve closed. See “Base Component Flow When
Stopped.”
To clear Indication

Flow [B] at Stopped

After locating the cause and taking preventive action, press RESET to clear the alarm indication. Then,
restart the coating operation.
(1) The learning was not correctly performed (the valve response timing is wrong).
(2) A malfunction of the hardener mixing valve
(3) Disorder of or air leak from the intrinsically safe explosion-proof solenoid valve
Cause

(4) The flow meter body is affected by noise (flow meter and sensor connection is loose).
(5) The flow meter cable is affected by noise from a high tension (200VAC) cable or such.
(6) Corona discharge from the static gun is acting as noise.
(7) A robot has been installed near the mixing unit.
(1) Perform the learning operation again. See 14-4 “Learning.”
(2) Check the pilot air tube. Overhaul and clean the hardener mixing valve and replace consumable parts.
*Note: When assembling, make sure to fill a packing protective solution. <Part No., 3979-1>
(3) Check the pilot air tube. Replace the intrinsically safe explosion-proof solenoid valve with a new one.
Remedy

(4) Ground the flow meter body and shielded wire of the flow meter cable.
(5) Modify to avoid crossing with another cable.
(6) Modify the routing so that the static gun will not draw near (within 1m of) the mixing unit. If it inevitably
draws near the mixing unit, turn off the static gun.
(7) Correctly ground the ACW mixing unit.
(6) Mode being changed
Description

Indicated when the trigger (air flow switch) signal is not detected during the mode change or when the spray is
stopped during the filling or flushing process.
To clear Indication

Mode Change in Process

After locating the cause and taking preventive action, press RESET to clear the alarm indication. Then,
restart the coating operation.
(1) Disorder of the air flow switch
Cause

(2) The trigger was not pulled within 20 seconds after the start of mode change.
(3) The spray was stopped during the mode change.
(1) Replace the air flow switch.
Remedy

(2) Press the mode select button while pulling the trigger. Start spraying within 20 seconds after that.
(3) Continue spraying during the mode change.

64
(7) Test/Learn in Process
Description

Indicated when the spray gun trigger is released during the learning operation or when the paint flow is not
detected by the flow meter during the mixture ratio test (optional).
Indication

Test/Learn in Process

Press RESET to clear the alarm indication. Stop the test or learning at this time. If the alarm occurs
To clear

during the learning operation, start it again from the beginning and, if it occurs during the test, locate the cause
and take corrective action before restarting the test.
<Learning>
(1) The spray gun trigger was released during the learning operation.
(2) No atomization air is supplied to the spray gun. (The air cock is closed or the air pressure is zero.)
Cause

(3) Disorder of the air flow switch. (The internal magnet switch does not function.)
<Test>
(1) The metering valves are closed or not fully open.
(2) Hardening in the Teflon tube downstream the metering valve
(3) Clogged flow meters. (The flow meters do not count up when the paint is sprayed through the tube.)
<Learning>
(1) Do not release the spray gun trigger.
(2) Supply atomization air to the spray gun.
Remedy

(3) Replace the air flow switch.


<Test>
(1) Open the metering valves.
(2) Replace the Teflon tubes. Overhaul and clean the tube joints.
(3) Overhaul and clean the flow meters.

(8) Base Component Flow Too High


Description

Indicated when the flow rate rises above 4,000mL/min (fixed limit) during the base component supply.
To clear Indication

Flow [A] Too High

After locating the cause and taking preventive action, press RESET to clear the alarm indication. Then,
restart the coating operation.
Cause

(1) Too much flow. (Take special care when two or more guns are used.)
(2) The feeder (pump) runs with nothing in it to feed air.
Remedy

(1) Reduce the flow rate. Adjust using the regulator, etc.
(2) Fill the pump with the fluid.

65
(9) Hardener Flow Too High
Description

Indicated when the flow rate rises above 4,000mL/min (fixed) during the hardener supply.
Indication

Flow [B] Too High


Cause

(1) Too much flow. (Take special care when two or more guns are used.)
(2) The feeder (pump) runs with nothing in it to feed air.
Remedy

(1) Reduce the flow rate. Adjust using the regulator, etc.
(2) Fill the pump with the fluid.

(10) RAM initialized


Description

Indicated when the power has been off for 2 or 3 weeks. The counter value of paint quantity used displays
zero. This alarm can be displayed when delivered.
To clear Indication

Parameters Not Set

Press RESET to clear the alarm indication.


Cause

This alarm is indicated when the power has been off for a couple of weeks (2 or 3 weeks) as well as when
the memory of the ACW controller became faulty due to electricity, vibration, heat or moisture.
Remedy

66
16
16-1 ACW mixing unit
Breakdown

A fundamental unit consisting of mixing valves and flow meters.

For high-pressure
type

Qt
No. Part No. Part name Remark No. Part No. Part name Qty Remark
y
1 1960 Outer box 1 14 40338-024 Grounding lead 1
For low-pressure
5037 Mixing valve assy (L) 1 15 13-10410 3-point screw w/washer 1 M4×10
type
2 For high-pressure Hexagon socket head cap
5037-1 Mixing valve assy (H) 1 type 16 03-80610 screw 6 M6×10(plated)
See the detail in the next
3 page 1 17 37-10600 Plain washer 8 M6
4 134E-2 Drain valve 1 18 41-80600 Spring washer 8 M6 (plated)
See the detail in the next Hexagon socket head
5 page 2 19 03-80625 cap screw 2 M6×25(plated)
Cross-recessed pan-head
6 4920-031 Collar A 1 20 68-10430 machine screw 6 M4×30
7 Missing number − − 21 3444 Return hose 1 Not shown
For low-pressure
8 4924-020 Solenoid valve set 1 2 solenoid valves 345-0049 Connector 1 type
22 For high-pressure
9 4924-021 Air purging assembly 1 247-4202 Hose joint 1 type
3 For low-pressure 23 4425-007 Gasket 1
10 342-0113 Bulkhead elbow
2 For high-pressure 24 134E-025 Hose nipple 1
Female bulkhead For low-pressure
11 374-0802 1 52C-0005 Teflon tube 1 type *1
union 25
12 347-0002-1 Elbow union 1 503-1003 Material hose 1 Joint hose
Grommet (For low For low-pressure
–pressure type) 3 52C-0005 Teflon tube 1 type *1
13 424-0088 Grommet (For High
φ22 26 For high-pressure
–pressure type) 4 503-1004 Joint hose 1 type

*1: Cut and adjust the length of the Teflon tube before use.

67
16-2 Mixing valve assy (L), Mixing valve assy (H)
Model: MVA-L (for low-pressure type) or MVA-H (for high-pressure type)
Part No.: 5037 (for low-pressure type) or 5037-1 (for high-pressure type)

For high-pressure type

For high-pressure type

See 16-1 “ACW mixing unit”.


No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
For low-pressure For low-pressure
4435 Mixing block L 1 type 345-0050 Elbow 1 type
1 For high-pressure
5 For high-pressure
4435-1 Mixing block H 1 type 249-4202 L-shaped hose joint 1 type
For low-pressure
2 5024-4 Mixing valve (R) 1 345-0016 Elbow 1 type
6 For high-pressure
3 5024-5 Mixing valve (L) 1 249-2202 L-shaped hose joint 1 type
4 22E-4202 Male/female joint 2 7 4920-031 Collar A 3

Detail of No. 3

*1

*1: For the high-pressure type, the parts enclosed by the chain line are not installed. 5035-1 is used instead.

See 16-6 “Flushing valve assembly (H).”


No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
For low-pressure
5035 Flushing valve assembly (L) 1 3 347-0002-1 Elbow union 1 type only
1
5035-1 Flushing valve assembly (H) 1 4 249-2202 L-shaped hose joint 1
For low-pressure For low-pressure
3620-1 Check valve (female) 2 type 345-0050 Elbow 1 type
2 For high-pressure
5 For high-pressure
3621-1 Check valve (female) 1 type 249-2202 L-shaped hose joint 1 type

68
Detail of No. 5

No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
For low-pressure
375-0004 Flow meter 1 type 6 247-4202 Hose joint 1
1 For high-pressure
375-0007 Flow meter 1 type 7 4920-031 Collar A 2
2 4924-007 Manifold 1 8 4924-036 Grounding lead 1
3 101-2007 O ring 2 P7 9 13-10410 3-poing screw w/washer 1 M4×10
4 4924-008 Male/female joint 1 10 15-10400 Hexagon nut 1 M4
Hexagon socket head cap
5 249-4202 L-shaped hose joint 1 11 03-80625 screw 2 M6×25(plated)

16-3 Outer box


Part No.: 1960

No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
For low-pressure
1 1960-001 Base 1 type 6 323-0048 Hinge 2
For high-pressure
2 1960-002 Cover 1 type 7 323-0006 Catch clip 4
3 1960-003 Lid 1 8 12-10306 2-point screw w/washer 16 M3×6
4 1960-004 Plate 1 P7 9 13-10410 3-point screw w/washer 4 M4×10
Cross-recessed
5 1960-005 Block 1 10 69-10508 countersunk head machine 12 M5×8
screw

69
16-4 Mixing block
Model: MBL-L (for low-pressure type) or MBL-H (for high-pressure type)
Part No.: 4435 (for low-pressure type) or 4435-1 (for high-pressure type)

No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
For high-pressure
1 4435-001 Block 1 6 4435-106 Spring 4 type
For low-pressure
2 4435-002 Valve body 4 4430-005 Gasket 4 type
7
For high-pressure
3 4435-003 Flange 1 1 4425-007 Gasket 4 type
4 4435-004 Flange 2 1 8 101-9012 O ring 8 P12
Hexagon socket
5 0231-009 Valve ball 4 9 03-80540 head cap screw 8 M5×40(plated)
For low-pressure
6 4426-006 Spring 4 10 41-80500 Spring washer 8 M5 (plated)
type

16-5 Flushing valve assembly (L)


Model: FVA-L (for low-pressure type), Part No.: 5035

No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
Hexagon socket head
1 135C-016 Manifold 1 5 244-4002 2 1/4”
plug
2 5027 Core valve 2 6 384-0601 Quick-connect joint 2 φ6 1/8”
3 5028-002 Plug 2 7 1381-030 Leak plug 2
4 363-0022 Resin cap 4

70
16-6 Flushing valve assembly (H)
Model: FVA-H (for high-pressure type), Part No. 5035-1

No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
1 135C-016 Manifold 1 7 1381-030 Leak plug 1
2 5027 Core valve 1 8 135E-041 Blind plate 1
3 5028-002 Plug 1 9 130-2010 O ring 1 S10
4 363-0022 Resin cap 2 10 41-80500 Spring washer 4 M5 (plated)
Hexagon socket Hexagon socket
5 244-4002 head plug 1 1/4” 11 03-80512 head cap screw 4 M5×12 (plated)

6 384-0601 Quick-connect joint 1 φ6 1/8”

16-7 Solenoid valve set


Part No.: 4924-020 (provided with two solenoid valves)

No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
Hexagon socket
1 4924-020-1 SOL harness 1 Not shown 4 378-0602 straight shank 4 φ6 1/4”
Intrinsically safe
2 411-0090 solenoid valve 2 5 326-0013 Muffler 4

3 384-0802 Quick-connect joint 2 φ8 1/4”

* It is recommended to keep a surplus number of 411-0090 intrinsically safe solenoid valves in stock.

71
16-8 Air purging assembly
Part No.: 4924-021

No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
1 4924-021-1 Manifold 1 4 376-0802 Quick-connect joint 2 φ8 1/4”
Female bulkhead Exhaust throttle
2 374-0802 union 1 φ8 1/4” 5 342-0163 valve w/muffler 1

3 342-0164 Straight elbow 1 φ8

16-9 Check valve (female)


Part No.: 3620-1 (for low-pressure type) or 3621-1 (for high-pressure type)

No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
Seat body For high-pressure
1 5026-202 1 3 4435-106 Spring 1
(female) type
For low-pressure
2 0231-009 Valve ball 1 4430-005 Gasket 1 type
4
For low-pressure For high-pressure
3 4426-006 Spring 1 4425-007 Gasket 1
type type

72
16-10 Core valve (for mixing valves, R and L)
Model: ACV1, Part No.: 5030

No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
1 5027-001 Body 1 11 1381-013 Gasket 1
2 5027-002 Seat case 1 12 1381-006 End plate 1
3 5027-003 Packing adjuster 1 13 1381-014 Spring 1
3-1 5027-003-1 Adjuster 1 14 5024-013 End cap 1
3-2 101-9003 O ring 1 P3 15 101-6003 O ring 1 P3
3-3 130-9012 O ring 1 S12 16 101-6034 O ring 1 P34
4 5024-204 Needle 1 17 130-2010 O ring 1 S10
5 1203-225 Packing gland 1 18 130-6005 O ring 2 S5
6 V850320105 V packing 4 19 130-9012 O ring 1 S12
Hexagon socket
7 1203-224 Packing gland 1 20 03-80580 head cap screw 2 M5×80 (plated)

Hexagon socket
8 1381-002 Cylinder 1 21 03-80590 head cap screw 2 M5×90 (plated)

9 1381-005 Piston 1 22 41-80500 Spring washer 2 M5 (plated)


Hexagon socket set
10 86-50506 screw 1 23 3370-001 Nameplate 1 Not shown

*1: If you need 5027-003-1, please order 5027-003.

73
16-10-1 Mixing valve, R
(R for right-hand (hardener), L for left-hand (base component))
Model: AMV-R1, Part No.: 5024-4

*Note: Make sure to fill a packing


protective solution.
<Part No., 3979-1>

No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
1 5030 Core valve 1 5 345-0015 Connector 1
2 5024-224 Plug 1 6 5021-026 Plug 1
3 101-2008 O ring 1 7 384-0601 Quick-connect joint 1 φ6-R1/8”
Hexagon socket
4 244-4001 head plug 1 R1/8” 8 376-0601 Quick-connect joint 1 φ6-R1/8”

16-10-2 Mixing valve, L


(R for right-hand (hardener), L for left-hand (base component))
Model: AMV-L1, Part No.: 5024-5

*Note: Make sure to fill a packing


protective solution.
<Part No., 3979-1>

No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
1 5030 Core valve 1 5 345-0015 Connector 1
2 5024-224 Plug 1 6 5021-026 Plug 1
3 101-2008 O ring 1 7 384-0601 Quick-connect joint 1 φ6-R1/8”
Hexagon socket
4 244-4001 head plug 1 R1/8” 8 376-0601 Quick-connect joint 1 φ6-R1/8”

74
16-11 Core valve
(CCV valve: Commonly used for base component/hardener/flushing, air purging, thinner and drain valves)
Each of the valves listed above mainly consists of a core valve with part No. 5027.
Model: ACV, Part No.: 5027

No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
1 5027-001 Body 1 11 1381-013 Gasket 1
2 5027-002 Seat case 1 12 1381-006 End plate 1
3 5027-003 Packing adjuster 1 13 1381-014 Spring 1
3-1 5027-003-1 Adjuster 1 14 5024-013 End cap 1
3-2 101-9003 O ring 1 P3 15 101-6003 O ring 1 P3
3-3 130-9012 O ring 1 S12 16 101-6034 O ring 1 P34
4 5027-004 Needle 1 17 130-2010 O ring 1 S10
5 1203-225 Packing gland 1 18 130-6005 O ring 2 S5
6 V850320105 V packing 4 19 130-9012 O ring 1 S12
Hexagon socket
7 1203-224 Packing gland 1 20 03-80580 head cap screw 2 M5×80 (plated)
Hexagon socket
8 1381-002 Cylinder 1 21 03-80590 2 M5×90 (plated))
head cap screw
9 1381-005 Piston 1 22 41-80500 Spring washer 2 M5 (plated)
Hexagon socket set
10 86-50506 screw 1

75
16-12 Mixing hose, L (for low-pressure type)
Model: AMH-LD5 (for φ6-4) or MH-LD8 (for φ8-6)
Part No.: 4433 (for φ6-4) or 4433-1 (for φ8-6)

No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
1 3254-001 Union 1 5 52C-0030 Teflon tube 1 φ8-6 3m
3254-002 Union 1 For φ6-4 570-0020 Teflon tube 1 For φ6-4 2m
2 6
3254-001 Union 1 For φ8-6 52C-0020 Teflon tube 1 For φ8-6 2m
342-0056 Swivel nut hose joint 1 For φ6-4 7 4432-001 Tube 1 φ3/8
3
342-0057 Swivel nut hose joint 1 For φ8-6 8 4425-014-3 Element 2 φ6.35
4 342-0057 Swivel nut hose joint 1 9 5254-039 Hose label 1

See 6 “Mixing Hose.”

16-13 Mixing hose, H (for high-pressure type)


Model: AMH-HS, Part No.: 4434

No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
1 4432-1 Static mixer 1 2 503-1030 Material hose 1 NH05030
1-1 4432-101 Mixer pipe 1 3 5254-039 Hose label 1 Not shown
1-2 4432-102 Element 2 Made of SUS

76
16-14 Drain valve
Model: DV, Part No.: 134E-2

No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
1 5027 Core valve 1set 7 1381-030 Leak plug 1
2 5024-224 Plug 1 8 134E-116 Manifold 1
3 363-0022 Resin cap 2 9 247-4202 Hose joint 1 MHJ2FF2TS
4 101-2008 O-ring 1 P8 10 Missing number 1
5 384-0601 Quick-connect joint 1 11 4920-031 Collar A 1
6 3370-001 Nameplate 1 Not shown 12 1353-046 Nameplate 1 Not shown

77
16-15 ACW1200 control unit
Model: ACW1200CUT, Part No. 26F1

No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
1 445-0127 ACW controller 1 4 467-0003 Barrier relay 1
ALB digital I/O
2 471-0005 terminal block 1 5 467-0012 SOL barrier 2
4 pcs.,
3 262A-007 Zener barrier 2 6 411-0094 Solenoid valve 1 coupled

No. Part No. Part name Qty Remark No. Part No. Part name Qty Remark
Bulkhead
1 3913 Air flow switch 1 6 374-0802 male/female union 3 For φ8

2 203-3002 Male/female elbow 1 7 382-0600 Bulkhead union 4 For φ6


3 325-0003 Ball cock 1 8 382-0800 Quick joint 1 For φ8
4 326-0013 Muffler 2 9 384-0802 Quick joint 1 For φ8
5 342-0164 Street elbow 4 For φ8 10 393-0600 Plug 8

78
17 List of Consumable Parts

Durable lives of the parts may vary depending on the type of paint used and coating and equipment conditions.
The values shown below should be taken as reference lives under the conditions of 20 working days per
month and 6 hours per day.

17-1 ACW mixing unit


(1) Mixing valve, R (part No. 5024-4) and mixing valve, L (part No. 5024-5)
Part No. Part name Qty Durable life Remark
V850320105 V packing 4 12 months Replace every 12 months.
5024-204 Needle 1 12 months Replace every 12 months.
101-9003 O ring (P3) 1 Until overhauled Replace when overhauled.
130-9012 O ring (S12) 2 Until overhauled Replace when overhauled.
1381-013 1 Until overhauled Replace when overhauled.
101-6003 O ring (P3) 1 Replace as necessary.
101-6034 O ring (P4) 1 Replace as necessary.

(2) Core valve (commonly used for flushing valve assembly (thinner and air purging) and drain valve)
Part No. Part name Qty Durable life Remark
V850320105 V packing 4 24 months Replace every 24 months.
5027-004 Needle (for φ2)
1 24 months Replace every 24 months.
5027-104 Needle (for φ4)
101-9003 O ring (P3) 1 Until overhauled Replace when overhauled.
130-9012 O ring (S12) 2 Until overhauled Replace when overhauled.
1381-013 Gasket 1 Until overhauled Replace when overhauled.
101-6003 O ring (P3) 1 Replace as necessary.
101-6034 O ring (P4) 1 Replace as necessary.

(3) Flow meter


Part No. Part name Qty Durable life Remark
134-9132 O ring (exclusive) 1 Until overhauled O ring around flow meter gear
101-2007 O ring (P7) 2 Until overhauled O ring for manifold

* It is recommended to keep a surplus number of flow meters as single units in stock.


Part No. Part name Type Remark
375-0004 Flow meter For low-pressure type MAX1000ml/min
375-0007 Flow meter For high-pressure type MAX 2000 ml/min

(4) Mixing block, L (part No. 4435) and mixing block, H (part No. 4435-1)
Part No. Part name Qty Durable life Remark
Commonly used for low- and
0231-009 Valve ball 4 24 months high-pressure types
4426-006 Spring 4 24 months For low-pressure type
4435-106 Spring 4 24 months For high-pressure type
101-9012 O ring (P12) 4 Replace as necessary.

(5) Miscellaneous
Part No. Part name Qty Durable life Remark
Intrinsically safe solenoid Replace solenoid valve as a single
411-0090 2 12 months
valve unit.
3620 Check valve (female) 2 Replace as necessary. For low-pressure type
3620-1 Check valve (female) 1 Replace as necessary. For high-pressure type
Packing protective 200ml (See mixing valve, R, L overhaul
3979-1 1 Replace as necessary.
solution drawing)

17-2 ACW control unit


Part No. Part name Qty Durable life Remark
3913 Air flow switch 1 Replace as necessary. For hand gun
467-0012 SOL barrier 2 Replace as necessary. For intrinsically safe solenoid valve

* For the paint regulators, pumps (feeders) and other devices, see the relevant instruction manuals.

79
18
18-1 Mixing valves
Overhauling and Maintenance

(1) Remove the mixing block. (2) Remove the valve. (3) Remove the end cap.
Loosen the joint using a (19mm) Remove two hexagon socket head Remove the end cap using a (27mm)
spanner and remove the mixing block cap screws together with spring spanner and remove the spring.
from the manifold of the flow meter. washers using a (4mm) wrench and
remove the valve.

(4) Remove the hexagon socket head (5) Overhaul. (6) Remove the packing adjuster.
cap screws. The assembly can be overhauled as Loosen and remove the packing
Remove the remaining two hexagon shown above. Replace the gasket adjuster by prying with a (8mm)
socket head cap screws (80mm long) and other parts. spanner as shown above.
using a (4mm) wrench.

(7) Measure the needle dimensions. (8) Loosen the plug. (9) Overhaul.
Before overhauling, measure and Loosen the plug using a (2.5mm) The assembly can be overhauled as
note the needle dimensions as wrench and (8mm) spanner and shown above. Do not remove the
assembled. replace the needle. plug from the piston as it may be lost.

For part Nos. of replacement parts, see 17 “List of Consumable Parts.”

80
(10) Replace consumable parts. (11) Wash parts. (12) Regain the needle dimensions.
Remove the packing adjuster from When overhauling, wash parts in After replacing the needle and V
the needle and replace the needle contact with the paint. packing, regain the noted needle
and V packing. dimensions as assembled.

(15) Install the hexagon socket head


(13) Fix the needle to the position (14) Install the packing adjuster.
cap screws.
Tighten the hexagon socket head cap Insert a spanner (HEX8) as shown
Replace the gasket and assemble
screw using a (2.5mm) wrench and a above and fully tighten the packing
parts. Tighten the hexagonal
(8mm) spanner. adjuster.
socket head cap screws (80mm
Tightening torque: 1.5 Nxm *1
long) using a (4mm) wrench.

(16) Install the end cap. (17) Install the valve. (18) Install the mixing block.
Insert the spring and install the end Insert the spring washers and install Install the mixing block to the manifold
cap. (Use a 27mm spanner.) the two socket head cap screws of the flow meter using a (19mm)
(90mm long) using a wrench (4mm). spanner.

For part Nos. of replacement parts, see 17 “List of Consumable Parts.”


*1: Tightening a hexagon socket head cap screw with a strong force could lead to breakage of screws or
needles. In this case, therefore, lightly tighten the hexagon socket head cap screw to the end, and
retighten 10 to 20 degrees (tightening torque: 1.3 to 1.6 Nxm).

81
18-2 Flushing valve assembly

(1) Remove the flushing valve


(2) Remove the valve. (3) Remove the end cap.
assembly.
Remove two hexagon socket head Remove the end cap using a (27mm)
Open the body and remove the two
cap screws together with spring spanner and remove the spring.
hexagon socket head cap screws
washers using a (4mm) spanner and
securing the hose joint to the
remove the valve. No air purging
flushing valve assembly, using a
valve is provided for the
(5mm) wrench.
high-pressure type.

(4) Remove the hexagon socket head (5) Overhaul. (6) Remove the piston.
cap screws. The assembly can be overhauled as Remove the piston from the cylinder.
Remove the remaining two hexagon shown above. Replace the gasket
socket head cap screws (80mm long) and other parts.
using a (4mm) wrench.

(7) Measure the needle dimensions. (8) Loosen the plug. (9) Remove the packing adjuster.
Before overhauling, measure and note Loosen the plug using a (2.5mm) Remove the packing adjuster using a
the needle dimensions as assembled. wrench and (8mm) spanner and (8mm) spanner.
replace the needle. The plug should
only be loosened.

For part Nos. of replacement parts, see 17 “List of Consumable Parts.”

82
(10) Remove the V packing. (11) Wash parts. (12) Regain the needle dimensions.

Remove the packing adjuster and When overhauling, wash parts in Install a new needle and regain the
remove and replace the V packing. contact with the paint. noted needle dimensions as
assembled.

(15) Install the hexagon socket head


(13) Fix the needle to the piston. (14) Install the packing adjuster. cap screws.
Tighten the hexagon socket head cap Install the V packing and tighten the Replace the gasket and assemble
screw using a (2.5mm) wrench and a packing adjuster using a (8mm) parts. Tighten the hexagonal socket
(8mm) spanner. spanner. head cap screws (80mm long) using
Tightening torque: 1.5 Nxm *1 a (4mm) wrench.

(16) Install the end cap. (17) Install the valve. (18) Install the flushing valve assembly.

Insert the spring and install the end Insert the spring washers and install Open the body and install the two
cap. (Use a 27mm spanner.) the two socket head cap screws hexagon socket head cap screws.
(90mm long) using a wrench (4mm). Then, install the hose joint.

For part Nos. of replacement parts, see 17 “List of Consumable Parts.”


*1: Tightening a Hexagon socket head cap screw with a strong force could lead to breakage of screws or
needles. In this case, therefore, lightly tighten the hexagon socket head cap screw to the end, and
retighten 10 to 20 degrees (tightening torque: 1.3 to 1.6 Nxm).

83
18-3 Flow meter
Reduce the pump (feeder) pressure to zero or flush the circuit from the pump to the ACW mixing unit
before overhauling.

10
(2) Remove the flow meter (step 1).
(1) Remove the flow meter cable.

Remove the two hexagon socket
Open the body and disconnect the head cap screws having no washer
flow meter cable connector. from the bottom of the body using a

(5mm) wrench.

(3) Remove the flow meter (step 2). 1


(4) Replace the O ring.
The hexagon socket head cap
When using the high-pressure type,
screws to be removed are the two
never fail to replace the two O rings
ones having no washer (25mm long).
of the manifold. See 17 “List of
Removing them separates the
Consumable Parts.”
manifold and flow meter.

Hexagon socket head cap


1
screw (M6)
2 Housing
3 O ring <134-9132>
4 Shaft
5 Gear
6 Upper cover
7 Amplifier case
8 Mounting screw
(6) Overhaul the amplifier. 9 Case lid
(5) Overhaul the amplifier. Remove the mounting 10 Grounding plate
Remove the case lid. (cross-recessed head) screws and
remove the amplifier case from the * Not to affect the flow meter performance
and calibration after installation, the parts
flow meter body. except the O ring (No. 3) can only be
* Do not rotate the amplifier case. ordered as an assembly.
* Do not wet the printed board with See 17 “List of Consumable Parts.”
solvent.

84
(7) Overhaul. (8) Remove the cap screws. (9) Remove the cap screws.
The assembly can be overhauled as Remove the six hexagon socket head Install two cap screws as shown
shown above. Take care not to lose cap screws using a (5mm) wrench. above and loosen the body using a
the grounding plate. screwdriver as a lever.

(12) Overhaul and clean the gears and


(10) Overhaul the body. (11) Overhaul the body.
shafts.
Install two cap screws as shown Slowly separate the upper cover and
Remove the gears and shafts and
above to facilitate the overhaul. housing. The cap screws serve as
wipe out using clean solvent and a
guides to facilitate the removal.
soft brush or waste cloth. Take care
not to damage or gouge the parts.

(15) Check.
Install the flow meter with the reverse
procedure of disassembly. Turn on
the power switch and fill the system
with two-component paint to check
the performance and check for a
while that the flow rate is smoothly
counted up. Also check for fluid
leak.
(13) Clean all parts. (14) Assemble.
Clean the shaft and gear mounting When assembling, align with the
sections, whole gears and sections of mark on the side and tighten the cap
the upper cover and housing in screws until the gap between the
contact with the gears. Take care upper cover and the housing is
not to damage or gouge the gears, eliminated.
housing and other parts. Replace Tightening torque: 12N-m
an O-ring 134-9132 with a new one if
required.
* Lint or hair from the waste cloth or For part Nos. of replacement parts, see 17 “List of Consumable Parts.”
brush shall not stick to any part.

85
19
19-1
Inspection Items

Pre-work inspection
Check the following items at the start of the everyday work.

Units of ACW1200
Check
Check item Criteria Corrective action
method
Fluid leak from Check with No fluid leak allowed. x Reduce the fluid pressure to zero and
base component eyes. tighten packing adjuster of valve.
mixing valve x Overhaul valve and replace packing.
Fluid leak from Check with No fluid leak allowed. x Reduce the fluid pressure to zero and
hardener mixing eyes. tighten packing adjuster of valve.
valve x Overhaul valve and replace packing.
Error/alarm indication Check with No error/alarm x Locate and remove the cause so that no
on ACW controller eyes. indication allowed. error or alarm will be indicated. See 15
display Check on “Troubleshooting.”
display.
Air supply pressure Check with The pressure gauge x Raise the air pressure.
to control panel eyes. shall read 0.4MPa or x Check air hose for bends.
higher.
Air pressure at Check with The pressure gauge x Raise the air pressure.
intrinsically safe eyes. shall read 0.4MPa or x Check air hose for bends.
solenoid valves higher.

Feeders
Check
Check item Criteria Corrective action
method
Pump (feeder) Check with Pump shall smoothly x Replace packing and ball.
performance eyes. function. x Overhaul pump.

Fluid leak from SUS Check with No fluid leak allowed. x Tighten pipe joints.
tank eyes. x Replace packing.
Nitrogen gas leak Stop No fluid leak allowed. x Replace packing at SUS tank lid.
from SUS tank nitrogen gas Pressure gauge See 9 Hardener Tank.
supply and reading shall not
check for change.
pressure
changes.
Air pressure from air Check with Pressure gauge x Raise the air pressure.
booster eyes. reading shall reach or x Check air booster.
exceed necessary
pressure.
Fluid leak from paint Check with No fluid leak allowed. x Overhaul regulators.
regulators eyes.

Pressures at paint Check with Base component and x Hardener and base component pressures shall
regulators eyes. hardener pressures be the same or the former shall be about 10%
shall be the same. higher during the mixing process.
* Pressure gauge may be out of order. Reduce
the primary fluid pressure to zero to check that
pressure gauge reads zero.

86
Feeders
Check
Check item Criteria Corrective action
method
Pulsation of fluid Check with No pulsation allowed. x Raise the pump pressure.
flow pressure * Variations shall not x Replace pump with a one that has a higher
gauge. exceed 10%. capacity.
Check with x Install the pulsation controller.
eyes.
Remaining quantity Check with A sufficient quantity x Replace gas bomb.
of nitrogen gas pressure shall remain. x Refill before bomb becomes empty.
gauge.
Check with
eyes.
Quality of air from x Take action according to the instruction manual
air drier for air drier.
* Drier using silica gel or such shall be replaced
when silica gel needs replacement.
Remaining flushing Check with Necessary quantity for x Refill flushing fluid.
fluid quantity eyes. flushing x 1.5 * Keep tank full of flushing fluid.

19-2 Inspection after work


Check the following items at the end of the everyday work.

Check
Check item Criteria Corrective action
method
Error/alarm Check with No error/alarm x Locate and remove the cause so that no error or
indication on ACW eyes. indication allowed. alarm will be indicated. Never fail to flush after
controller display Check on that.
display. See 15 “Troubleshooting.”
Flush check W” lamp Flushing fluid shall x Pull spray gun trigger with W lamp lit until a
on display come out of gun head. sufficient quantity of flushing fluid comes out of
“W” lamp shall be lit. gun.

Air cap and nozzle Check with Contaminants and x Remove air cap and nozzle and remove
cleaning eyes. clogging matter in air contaminants and clogging matter using a brush.
spray hole or nozzle

19-3 Weekly inspection


Check the following item once a week.

Check
Check item Criteria Corrective action
method
Quality and Air filter Shall be free of dirt, oil x Remove wastes in air filter.
pressure of air from clogging and water. x Replace filter.
pumps, etc. matter

Quality of air from Air filter Shall be free of dirt, oil x Remove wastes in air filter.
intrinsically safe clogging and water. x Replace filter.
solenoid valves matter

87
19-4 Monthly inspection
Check the following items every month.

Check
Check item Criteria Corrective action
method
Regulation by paint Check with Shall correctly regulate x Overhaul regulator.
regulators eyes. pressure. x Replace pressure gauge.

Paint filter in pump Check with No filter clogging x Clean or replace filter.
eyes. matter and
contaminants allowed.
Clogging matter in Check with No filter clogging x Clean or replace filter.
paint filter at eyes. matter and
hardener tank contaminants allowed.
Film formation in Check with No film formation x Replace paint hoses.
paint hoses eyes. allowed.

19-5 Regular inspection


Check the following items every 3 to 6 months.

Check
Check item Criteria Corrective action
method
Leak from paint Check with No fluid leak allowed. x Tighten hose joints.
hoses eyes. x Replace paint hoses.

Contamination of Overhaul Accumulated x Clean pre-mixer and overhaul and clean or replace
static mixer and check contaminants and static mixer element.
with eyes. paint

Responsiveness of Learning 30% or higher than the x Replace consumable parts of valves (V packing,
mixing valves level obtained by needle and O ring).
(base component learning at the time of x Replace intrinsically safe solenoid valves.
and hardener) delivery

* The “learning” is a function to determine the responsiveness of valves. After the learning operation, note
the settings.

See 14-4 “Learning.”

19-6 Miscellaneous
Check the following items as necessary.

Check
Check item Criteria Corrective action
method
Flow meter Indication Shall be smoothly x Overhaul or replace flow meter.
operation of flow rate counted up.

See 17 “List of Consumable Parts” and 18 “Overhauling and Maintenance.”

88
20
20-1
Assignment of I/Os

Inputs and outputs on ALB terminal block


Station No. I/O indication on liquid crystal IN10
10
(preset No. of terminal block) display OUT10

Designation Remark

0 READY (ON/OFF) Input signal from local operation panel(Coating mode “READY”)

1 2K Input signal from local operation panel(Two-component paint filing “2K”)

2 Wash Input signal from local operation panel (Flushing “W”)

3 Solvent Input signal from local operation panel(Flushing solvent “SOLVENT”)


IN

4 Air flow switch Connected with atomization air for spray gun. Linked with mixture control

5 Error signal from outside Alarm is indicated on display when signal is received

0 Base component mixing valve For controlling base component mixing valve (intrinsically safe solenoid valve)

1 Hardener mixing valve For controlling hardener mixing valve (intrinsically safe solenoid valve)

2 Thinner valve For controlling flushing valve

3 Air valve For controlling air purging valve


OUT

5 Drain valve For controlling drain valve

6 Mode being changed Issued during mode change between flush and 2K

7 High voltage generation permitted For controlling 100V outlet (BPS105 supported)

20-2 Input and outputs on ACW controller


Designation Function Specification Remark
OUT1 Relay output 1a contact DC30V 2A For error/alarm buzzer
OUT1C Relay output 1c contact DC30V 2A
OUT2 Relay output 2a contact DC30V 2A For error/alarm lamp (red)
OUT2C Relay output 2c contact DC30V 2A
TR1+ HLS1 communication + 6MBps transfer
TR2+ HLS2 communication + 6MBps transfer For communication with exclusive terminal block
TR1- HLS1 communication - 6MBps transfer (ALB)

TR2- HLS2 communication - 6MBps transfer


SP12+V 12VDC output DC12V Power supply to flow meter barrier (+)
SP12-V DC12V GND DC12V Power supply to flow meter barrier (-)
Up to 3.5VDC Input terminal for pulse signals from base
IN3 Base component 1/V
when on component flow meter
Up to 1.0VDC Input terminal for pulse signals from hardener flow
IN4 Hardener 1/V when off meter
RD1+ RS422 reception Communication cable for exclusive printer (optional)
SD1+ RS422 transmission Communication cable for exclusive printer (optional)
RD1- RS422 reception Communication cable for exclusive printer (optional)
SD1- RS422 transmission Communication cable for exclusive printer (optional)

89
21 Settings Recording Sheet
<<Settings Recording Sheet for ACW1200>>
General settings
Item Indication on LCD Default Setting Necessity
(1) Mixture ratio Mixture ratio 1.00 €
Usable period
(2) Pot Life 1 hr 00 min hr min €
(pot life)
Correction factor for
(3) base component flow [A] Correct Pulse 1.000 ×
meter
Correction factor for
(4) [B] Correct Pulse 1.000 ×
hardener flow meter
Air 2.5 (high pressure 0.0) sec
Thinner 1.5(high pressure 60.0) sec €
(5) Flushing conditions
Times 8 (high pressure 1) Times *1
Filling 15 (high pressure 40) sec
c
(6) Thinner filling time Thinner filling time 0 sec
*2
First Air Purge
Initial air purging
(7) W 15.0 (high pressure 0.0) sec €
conditions
2K 15.0 (high pressure 0.0) sec *1
Drain valve opening
(8) Drain time 0.0sec sec ×
time (unchangeable)

Password <0001>
Item Indication on LCD Default Setting Necessity
Base component flow 0.115 mL/pls ×
(1) [A] Flow/Pulse mL/pls
meter (high pressure 0.230mL/pls) *1
0.115 mL/pls ×
(2) Hardener flow meter [B] Flow/Pulse mL/pls
(high pressure 0.230mL/pls) *1
0
Trigger interlock for
(3) Auto Trigger in Flushing (0: Ineffective, 1: c
flushing/filling
Effective)
Error lamp status in 1
(4) Alarm Lamp Pattern c
case of error (0: Lights, 1: Blinks)

Password <0002>
Item Indication on LCD Default Setting Necessity
Hardener pulse input
(1) [B] on to pulse input delay 40 msec msec ×
time
Base component
(2) [A] off to pulse stop delay 40 msec msec ×
pulse stop time
Hardener pulse stop
(3) [B] off to pulse stop delay 40 msec msec ×
time
Fluid velocity in
(4) 4-pulse width in learning 40 msec msec ×
learning
0 pulse
Pulse number in
(5) Pulse number in learning 5 pulse ×
learning
10 pulse

The necessity of setting change is indicated by symbols.


€: To be always changed according to the specifications. |: To be changed according to the specifications.
×: Not to be changed except in special cases.
*1: The setting shall be the one when initializing the high-pressure type. See 12-3-5 “Password <0101>.”
*2: Applicable to ACW1200 controller ver. 2.02 and successors.

90
22 Scope of Guarantee

z ASAHI SUNAC Corporation, as the manufacturer of the equipment, shall guarantee to the first purchaser
of the equipment against any defects in its design, manufacture or markings for the period of 12 (twelve)
months from the date of purchase.

z If there is any defect on the equipment that may be attributed to a wrong design or bad workmanship,
please return it to us with the freight prepaid. In case, after the investigation at our plant, it is proved that
we are responsible for the defect, the equipment shall be repaired or replaced with new one at out cost
and returned to you with the freight prepaid and the freight paid by you shall be refunded.

z This warranty shall not apply to any equipment having a defect caused by natural wear, corrosion,
carelessness, accident, Act of God, incorrect installation, rough operation, handling without following
instructions in this manual and modification not approved by us and, in this case, the cost of repair or
replacement and return freight shall be borne by the customer.

z If the defect is caused by the use of the equipment with hoses and/or guns made by another
manufacturer and not approved by us, this warranty shall not apply. In this case, the cost of repair or
replacement is separately quoted with the handling conditions presented.

z For any accessories or parts of the equipment purchased and used by us, the warranty terms established
by the manufactures of such accessories or parts shall apply.

z The ASAHI SUNAC’s responsibility for product warranty shall be deemed as completed by free repair or
replacement of part(s) of the equipment.

z ASAHI SUNAC shall not be responsible for any damage or loss caused for any reason beyond our
control.

zWhen transferring this machine to another owner, attach the instruction manual to the machine.·
z This machine has been manufactured according to the laws and legislations of Japan and may only be
used in Japan.
When using the machine in another country, it is necessary to observe the safety standards in that
country.

5th Edition: January 9, 2007

91
〔Memo〕
Leading Manufacturer of Coating FA Systems
ASAHI SUNAC CORPORATION
Head office & Factory: 5050 Asahimae-cho, Owariasahi, Aichi 488-8688 Japan TEL 81-561-52-0717 FAX 81-561-54-8847

e-mail: ctrd01@sunac.co.jp

Coating Technology Center: 5050 Asahimae-cho, Owariasahi, Aichi 488-8688 Japan TEL 81-561-53-1226 FAX 81-561- 53-2722

Tokyo office: 2-16-3, Uchikanda, Chiyoda-ku, Tokyo 101-0047 Japan TEL 81-3-3254-0911 FAX 81-3-3258-1968

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