EASYDRY SPRAYTRON - kOmbiTRON

EASYDRY RETROFiT

TEchNicAl DATA

Measures and dataEasydry Retrofit code:Easydry Spraytron and Kombitron code:Booth width:Booth length:Booth Height:Weight:Maximum size of objects which can be painted:Time for installation:Warranty:

Compressed airLine pressure:Connection tube size:

Motors

Overhead crane

Rails

20202021

min 3,90 mt - max 4,50 mtmin 6,00 mt - max 10,00 mt

min 2,50 mt280 kg

2 x 6 x h 2 mth 24

12 months

min 12.7 - max 14.7 ftmin 19.6 - max 32.8 ft

min 8.2 ft617.2 lb

6.5 x 19.6 x h 6.5 ft

8 bar8x10 ØixØe mm

The overhead crane is driven by an ATEX-certified 24V DC motor equipped with an ENCODER for con-tinuous position control.

The gantry structure of the overhead crane accom-modates all motor drives, installations and sensors required for robot operation. The gantry structure is made up of:two motor-driven side carriages that slide on alu-minium runways installed in the booth.A frame connecting the two carriages for the slid-ing movement of the vertical lamp units.Two air-operated trolleys drive the horizontal lamp movements.The top section of the overhead crane is totally enclosed to prevent overspray dust from building up inside.

Easydry has its own framework with 3 legs on each side of the booth that bear the full weight of the robot without damaging or affecting the booth structure. During the drying cycle, the overhead crane slides on two aluminium rails that run across the full length of the booth.

Easydry is perfect for large-volume body shops with a large workforce.Everyone can operate it with just minimal training: this is a simple robot that can be adapted to the hand of each and every painter. It can perform a complete paint-and-dry job in just over half an hour and up to 12 jobs a day. In other words, it saves you one and a half hour per job on average, compared to your normal routine.

Control boxCard:Display:Keyboard:Supply voltage:Frequency:Controls voltage:Installed power (power input during first 3’:30”):

Control box

Keyboard and display

Monitoring and control system

Approval and QualityApproval:

Laser temperature control sensor

Automatic laser shape system

19.6x36.6”

2.7 lb/h

216.9 lb/h

microcontroller4 x 20 DIGITmembrane

400 V~ - 230 V~50/60 Hz

24 V~11,3 kW

EU: CE - ATEX II 3 G X Au: Compliant to Australian safety standards

AS/NZS 4114.1:2003 – AS 3814.1:2009US: cETLus Listed - Intertek 5000803

The electrical panel is located outside the booth, on the right or left side, and accommodates safety devices, contactors, relays, transformer and elec-tronic components (see details below).

Easydry is equipped with a membrane keyboard and a four-line display to allow for data manage-ment by operator.

The electrical panel accommodates a board with microcontroller that manages motor with encod-er, I/O signals and all other components.

Easydry features 3 laser sensors for dynamic temperature detection on each lamp unit.The LTC (Laser Temperature Control) sensor is ATEX certified and has been specifically developed and designed at Symach’s in-house research laboratory to avoid reflection and deterioration when measuring temperature on water base, metallic paint and different colours.

Easydry features an LLS (Laser Level Shape) system that detects varying vehicle and/or object heights as the vehicle/object moves along during the drying process and sends the information to the computer. The LLS system automati-cally moves the horizontal lamp up and down between the up and down positions to adjust to vehicle height, as is the case with the transition from vehicle roof to vehicle hood. The LLS system cannot rotate the horizontal lamp by 180° as the Robodry does. As a result, the bumpers left installed on the vehicle will not dry perfectly.

GasNo. of lamps:Dimensions:Power output:Hourly consumption - LPG (G31) at 12 mbar:Hourly consumption - Natural gas (G20) at 12 mbar:Power consumption (3’:30” only):Catalyser life:Implant power output:Hourly consumption - LPG (G31)at 12 mbar:Hourly consumption - Natural gas(G20) at 12 mbar:LPG gas (G31) / natural gas (G20) line pressure:Operating pressure LPG gas (G31)- Natural Gas (G20):Fitting size:

Control gas unit

Gas pipelines

6500x930 mm

16,4 kW

1,24 kg/h

1,66 cu.m./h1,88 kW

5000 h. - 30000 drying cycles98,4 kW

7,44 kg/h

9,96 cu.m./h

20/25 mbar

12 mbar1”G

The DrytronicPlus lamp can run on LPG or natu-ral gas with no difference in performance. The gas unit is installed outside the booth and includes 1 main solenoid valve, 3 NC (Normally Closed) so-lenoid valves - one per lamp unit - and a safety pressure valve that maintains proper pressure. Gas is never present inside the booth where the Easydry is installed, because it is only delivered to the lamps when drying is activated. Connection to customer’s plant mains is ensured by a 1” pipe.

All gas pipes are certified flexible stainless steel corrugated pipes for moving applications and are guaranteed for continuous rotation in cable drag chains. The pipes are jointless and are robot laser welded at the manufacturer’s factory.

LOOK AT THE FUTURE

Software

Treatment size entry

Lamp unit selection

Drying formula selection and set-up

Treatment reports

The main screen allows access to the following programmes:a) Treatment size (start / end of treatment).b) Lamp unit selection (right, left and horizontal units).c) Drying formulas (formula entry and editing).d) Drying temperature display (for each lamp unit).e) Manual controls (overhead crane movements).f) System stop (end of day switch off).

Entering the data required for the treatment is a simple, intuitive procedure: the screen holds the fields for treatment start and end sizes. The operator uses the suitable key to increase the treatment start figure until obtaining the de-sired setting and repeats the process with the treatment end field. Treatment start and end points are determined by operator so as to suit the part to be dried, using the rule available on the rail inside the booth for reference.

The operator chooses to use one, two or all three lamp units as required by the drying job, and selects the right, left or horizontal unit in the suitable field.

After entering treatment size and selecting lamp units, the operator chooses the drying formula from a database that holds formulas for all types of paint. A formula is a set of parameters and the work cycle which the robots performs automatically to dry a specific products, a given portion of a vehicle or of loose parts. Formula parameters can be edited in the formula screen before pressing start. This function allows operator to customise a drying formula as required. For instance, the operator may want to edit a formula to dry a particularly thick coat of paint, or materials that are very sensitive to temperature, to ensure optimal drying quality.Editable parameters are as follows:formula temperature, for special jobs or when drying materials with special requirements.Formula speed, for harder or softer drying depending on coat thickness, among other things.Number of passes when drying objects made of materials that are very sensitive to temperature.Formula database entry and editing: the operator can edit or enter customised formulas, also according to his prefer-ences or technique.

Easydry provides reports on the number of treatments and total hours worked for jobs done.

DRYTRONicPlUS TEchNOlOGY lAmP

software

The Drytronic lamp generates energy by means of a catalytic chemical reaction. This reaction is achieved by using a catalyser that, once activated, can break down gas molecule and separate hydrogen from carbon. After going through the catalyser, hydrogen reaches lamp outer surface and, by getting in contact with oxygen, triggers the catalytic reac-tion that generates radiation, i.e. emitting infrared electromagnetic waves in the 0.76 and 3.5 micron wavelength spectrum.

ControllerEach lamp is fitted with an electronic controller that constantly monitors catalyser efficiency and triggers an emer-gency condition whenever it detects an abnormal event or depletion.

Horizontal lamp unitThe horizontal lamp unit is made up of two lamps and features an automatic pneumatic motion system that moves it up and down to adjust it to vehicle height according to the readings of the LLS (Laser Level Shape) system. This system automatically adjusts the horizontal lamp to the height of the vehicle or object to be dried maintaining the proper distance from the surface, while the “DryingControl” system ensures proper drying.

Vertical lamp unitsThe right and left vertical lamp unit is made up of two lamps installed on two manual carriages that can be shifted forward and backward across overhead crane width to adjust lamp distance to the width of the vehicle or object to be dried as required. Adjustment is carried out only during robot installation.

Three independent lamp unitEasydry features 3 independent lamp units that can operate individually, two at a time or three at a time during treatment. The lamp unit is equipped with an automatic LTC (Laser Temperature Control) system that monitors drying and adjusts temperature to suit colour, type and thickness of substrate (iron, aluminium, plastic, fibreglass, etc.) and type of paint. Proper drying management according to the set formula is provided by the “DryingControl” software developed at the Symach research laboratories, that controls all formula parameters associated with sensors and Easydry automation system.

Treatment started

Treatment start

Manual controls

System stop

Language

DryingControl

The two DryingControl functions

The treatment-started window displays the temperature reading of the LTC system for each lamp unit, so operator can monitor the job on hand continuously. The exact progress of the treatment under way is also displayed.

The “Start” key starts the automatic drying treatment.

Easydry offers two push-buttons to manually control overhead crane movement for maintenance pur-poses.

Easydry has a main switch to stop the system and an emergency stop switch. When the robot remains unused for half an hour, an automatic device places it in the “Off” state.

Display language can be selected in the configuration section and all messages and indications will be displayed in the selected language.

Easydry drying treatment is controlled by an advanced monitoring and control software named “DryingControl”. The “DryingControl” software automatically controls drying treatment by coordinating the operation of all LTC (Laser Tem-perature Control) devices, of the robot system and of the Drytronic WLC (Wave Length Control) technology for fast, optimal drying. Operation is maintained within set temperature and exposition time at all times.

“Increasing or decreasing wavelength” The first function of “DryingControl” is the WLC (Wave Length Control) system, that promotes or slows down the chemical reaction in the lamps to increase or decrease the energy output at varying wavelength as required to obtain just the right paint reticulation.

“Gas Flow” Gas flow is controlled by the “Pop-Up” system that adjusts pressure and delivery to treatment.

Safety devices

Gas delivery only during the drying treatment

Gas nc solenoid valves

Air pressure valve

Catalyser control

Special pipes

Alarm devices safety pressure valve

Gas and solvent detector

Motor drive effort control

Control hardware and software

This robot is ATEX certified, which means it has been designed to operate in environments where potentially explosive gas mixtures can develop as solvents are released by paint products during the drying process.This certification guarantees that the product and its components are designed and manufactured to operate safely in this kind of environment.

Gas delivery is always cut off outside the booth, meaning that gas is only delivered when the drying treatment is in progress and all safety systems are active.

The gas control panel outside the booth features double-tier safety, with a first NC (normally-closed) main and three additional NC solenoid valves one for each lamp unit that are only activated when the drying treatment is active.

A pressure valve checks compressed air pressure to ensure the proper catalytic reaction is achieved.

Each lamp is fitted with a thermostat that monitors the proper operation of catalyser and heating element.

Gas supply pipes are flexible stainless steel corrugated pipes guaranteed to last 30,000 movements in cable drag chains, that require no on-site welding.

The gas control panel outside the booth accommodates a safety pressure valve to ensure the correct amount of gas is delivered at the right time.

A gas and solvent detector is installed inside the booth to monitor the internal environment at all times and detect any traces of gas during operation.

If a moving part hits an obstacle on its path, the robot is immediately placed in an alarm condition.

Hardware and software monitoring ensures proper operation of each and every component.

SAFETY DEvicES

AccESSORiES

Supporting beamCode:Dimensions:Beam supporting legs for booths with size door measuring up to 6 mt.

Surcharge special leg kitCode:Legs.Leg support.Adjustable foot.For booths extension from 4 mt to 4.5 mt.

Rail extensionCode:Supporting legs.Adjustable foot.Cable conduit.Right-hand measuring label.2 mt aluminum section.10.1 mt toothed belt.Booth rails extension from 8 mt to 10 mt.

20803 mt x 2 pieces

2081

2082

9.8 ft x 2 pieces

19.6 ft

13.1 to 14.7 ft

6.5 ft33.1 ft

26.2 to 32.8 ft

APPlicATiONS: wATER bASE

PPG - bASF - AkzO NObEl

AXAlTA

APPlicATiONS: clEAR cOAT

Drying

Drying

Drying

Drying

TOTAL TIME

TOTAL TIME

TOTAL TIME

1

1

1

3

2

2

2

4

1:30 miNUTES

1:30 miNUTES

2:00 miNUTES

1:30 miNUTES

6:00 miNUTES

4:30 miNUTES

6:00 miNUTES

1° + 2° Coat (without flash off)

1° + 2° + 3° Drop coat(without flash off)

1° + 2° Coat(without flash off)

3° Coat (Drop coat)

2:00 miNUTES

3:00 miNUTES

4:00 miNUTES

1:00 miNUTES

Symach srl - Via Cassoletta, 41/A Crespellano 40056 - Bologna - Italy

www.symach.cominfo@symach.com

Ph. +39 (0)51 963161