DÜRR TRAINING · Relation between paint booth and paint separation system as well as the basic structure of the paint separation system EcoDryScrubber Components and function Paint

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DÜRR TRAININGPAINT SHOP TECHNOLOGY

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TABLE OF CONTENTS

1 BASIC TRAININGSDÜRR PLANT BASICS ................................................................................................................................... 4

2 MAINTENANCE & OPERATIONPRETREATMENT & ELECTROCOATING ....................................................................................................... 5OVENS ............................................................................................................................................................ 6PAINT BOOTH & AIR SUPPLY UNITS ........................................................................................................... 7PAINT SEPARATION – EcoDryScrubber ....................................................................................................... 8PAINT SEPARATION – EcoDry X .................................................................................................................. 9DEIONIZATION SYSTEM (DI PLANT) .......................................................................................................... 10WASTE WATER PLANT ................................................................................................................................ 11AIR POLLUTION CONTROL – Ecopure® CRC & Ecopure® TAR ............................................................. 12CONVEYOR ................................................................................................................................................... 13RoDip® M / RoDip® E ..................................................................................................................................... 14

3 CONTROL SYSTEMSCONTROL SYSTEMS – BASICS .................................................................................................................. 15PROCESS PLCs – HARDWARE & SOFTWARE ........................................................................................... 16CONVEYOR PLCs – HARDWARE & SOFTWARE ........................................................................................ 17EcoDC MACS – HARDWARE & SOFTWARE ............................................................................................... 18RoDip®M/E – HARDWARE & SOFTWARE ................................................................................................... 19

4 VISUALIZATION & CCREcoScreen – ADMINISTRATOR ................................................................................................................... 20EcoScreen – ENGINEERING ....................................................................................................................... 21

CONDITIONS OF REGISTRATION AND PARTICIPATION ............................................................................................................................... 22

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Dürr

Tra

inin

g Le

vels LEVEL 1 – Beginner

Level 1 courses do not require specific prior knowledge, however participants should have a basic technical understanding of automotive production.

LEVEL 2 – Advanced Level 2 courses are designed for maintenance personnel and /or plant operators. Level 2 courses require successful completion of Level 1 courses or comparable certifications.

LEVEL 3 – Professional Level 3 courses are designed for skilled employees and technicians. Requirements for Level 3 courses are specified in respective course descriptions.

LEVEL 4 – ExpertLevel 4 courses are designed for technical experts (e.g. IT administrators). Requirements for Level 4 courses are specified in respective course descriptions.

PORTFOLIO

4

BASI

C TR

AIN

INGS

LEVEL 1

DÜRR PLANT BASICSCourse descriptionYou will learn how to read technical drawings and get an introduction into the basic structure of a paint shop with all its subsystems and technical relations.

Course no. A.01 / Duration: 2 Days

Content Basic structure of a paint shop » Process chain of a car body in a paint shop » Subsystems of a paint shop

Overview of conveyors » Types of conveyor elements (horizontal / vertical direction, turning movements, drive units)

Designation system of the plant » Hierarchy of the numbering system for plant labeling of mechanical and electrical components

Drawing types » Schematics » Conveyor and safety layouts » Material flow charts » Wiring diagrams

Overview of control systems in a paint shop » Hierarchy and components of control cabinets » Controls concept for process and conveyor elements

Operation concept » Local and central operation elements for process and conveyor plants

Practical exercises in classroom and in the paint shop

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Requirements: Level 1 – Dürr Plant Basics A.01

LEVEL 2

MAI

NTE

NAN

CE &

OPE

RAT

ION

Course number: B.01 b Duration: 2.5 DaysCourse number: B.01 a Duration: 5 Days

» Structure of the technical documentation » Maintenance tasks and cleaning / rinsing intervals according to maintenance list

» Exchange of spare parts and wear parts according to spare parts list

» Control cabinets of the plant » Safety instructions for maintenance and cleaning procedures

» Safety instructions for handling of chemicals » Operation concept (basic functions of the visualization)

PRETREATMENT & ELECTROCOATINGCourse descriptionIn this course you will learn how to maintain /operate the pretreatment and electrocoating system. Starting with structure and function, all relevant maintenance tasks as well as the operation of the system will be explained.

ContentBasic informationPainting process of a car body and chemical basics for the pretreatment and electrocoating process.

Components and functions » Zones of pretreatment and electrocoating » Schematics and plant structure » Bath conditioning components of pretreatment (e.g. filtration, temperature control or dosing equipment) » System components of electrocoating (e.g. anolyte system, ultrafiltration modules, dosing system)

Air balance of the tunnel » Supply air and exhaust air concept of the PT EC tunnel

» Safety instructions for operation of the PT EC plant and dosing of chemicals

» Operation concept » Basic functions » Automatic /manual mode » Central start on /off

» Adjust parameters for dosing » Selector switches on visualization » Local operation elements

Operation course Maintenance course

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LEVEL 2

MAI

NTE

NAN

CE &

OPE

RAT

ION


Course number: B.02 b Duration: 1 DayCourse number: B.02 a Duration: 2 Days

» Structure of the technical documentation » Maintenance tasks and intervals according to maintenance list

» Exchange of spare parts and wear parts according to maintenance instructions

» Setting of the air balance » Control cabinets of the plant » Safety instructions for maintenance and cleaning procedures

» Emergency entry and quick cooling » Operation concept (basic functions of the visualization)

OVENSCourse descriptionIn this course you will learn the maintenance /operation of the ovens in the paint shop. Starting with structure, function and air balance, all relevant maintenance tasks as well as the operation of the system will be explained.

ContentOven basics

» Oven design, drying process, oven properties » Oven zones (air seals, heating zones, cooling zones) » Heating and cooling units incl. Ecopure® TAR / burners

Air flow management » Exhaust air concept » Fresh air supply » Trouble shooting

» Safety instructions for operation » Operation concept

» Basic functions » Automatic mode / manual mode » Quick cooling » Central start on /off

» Adjust parameters » Local operation elements

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LEVEL 2

MAI

NTE

NAN

CE &

OPE

RAT

ION


» Structure of the technical documentation » Maintenance tasks and cleaning intervals according to maintenance list


» Setting of the air balance » Control cabinets of the plant » Safety instructions for maintenance and cleaning procedures (personal protection, ATEX areas)

» Local operation elements

PAINT BOOTH & AIR SUPPLY UNITSCourse descriptionIn this course you will learn the maintenance /operation of the paint booth with the appropriate air supply units. Starting with structure and function of the booth system, we will explain all relevant maintenance /operation tasks as well as the operation of the system.

ContentSystem overview of the paint booth

» Air supply and recirculation air units » Structure of paint booth with clean room » Connection to the paint separation system

Components and function » Components of air supply units (filter stages, temperature control systems, ventilation system) » Zones and levels of the paint booth

Air balance » Parameters for booth setting


» Basic functions » Automatic mode / manual mode » Maintenance mode » Central start on /off

» Adjust parameters to optimize performance » Local operation elements


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» Cleaning tasks and cleaning tools » Exchange of spare parts and wear parts according to maintenance instructions

» Control cabinets and pneumatic cabinets of the plant » Safety instructions for maintenance and cleaning procedures

» Operation concept (basic functions of the visualization) » Plant visit (silos and filter modules) and practical exercises


LEVEL 2

MAI

NTE

NAN

CE &

OPE

RAT

ION



Course descriptionIn this course you will learn the maintenance /operation of the paint separation system EcoDryScrubber.

ContentSystem overviewRelation between paint booth and paint separation system as well as the basic structure of the paint separation system EcoDryScrubber

Components and functionPaint separation process with filter modules, components of filter modules incl. pneumatic control system, operation modes

Material supply conceptLimestone supply and waste material removal from/to filter modules/silos

» Safety instructions for plant operation » Operation concept

» Basic functions of visualization » Adjust parameters to optimize performance

» Check history and create trends on visualization » Automatic /manual mode » Local operation elements at silos (filling / emptying procedure)

PAINT SEPARATION – EcoDryScrubber

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LEVEL 2

MAI

NTE

NAN

CE &

OPE

RAT

ION


Course number: B.05 b Duration: 0.5 DaysCourse number: B.05 a Duration: 1 Day

Course descriptionIn this course you will learn the maintenance /operation of the paint separation system EcoDry X.

ContentSystem overviewRelation between paint booth and paint separation system as well as the basic structure of the paint separation system EcoDry X

Components and functionPaint separation process in different filter stages, components of the filter trolleys, assembly of filter boxes, components of the filter exchange station, operation modes

Filter conceptIntervals for exchange of filter trolleys and filter boxes


» Basic functions » Adjust parameters to optimize performance

» Check history / trends of trolley weights » Practical exercises for exchange concept » Local operation elements at exchange station

PAINT SEPARATION – EcoDry X




» Local operation elements at exchange station

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Requirements: Level 1 – Dürr Plant Basics A.01 / Level 2 – Pretreatment & Electrocoating

LEVEL 2

MAI

NTE

NAN

CE &

OPE

RAT

ION


DEIONIZATION SYSTEM (DI PLANT)Course descriptionIn this course you will learn the maintenance /operation of the DI plant in the paint shop.

ContentSystem overviewProcess stages in the DI plant with reverse osmosis units or ion exchangers

Filtration technologiesTechnical details and comparison of different filtration technologies (macrofiltration, microfiltration, ultrafiltration, crossflow-membrane-filtration, reverse osmosis)

Chemical basicsComponents of water, types of particles contained in fresh/industrial water

Components and functionsStructure and function of water tanks, filter stages, reverse osmosis unit or ion exchangers and equipment for plant regeneration





» Safety instructions for operation of the DI plant and dosing chemicals

» Operation concept » Basic functions » Automatic /manual mode » Central start on /off

» Adjust parameters for DI water production » Selector switches on visualization » Local operation elements


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Requirements: Level 1 – Dürr Plant Basics A.01 / Level 2 – Pretreatment & Electrocoating

LEVEL 2

MAI

NTE

NAN

CE &

OPE

RAT

ION


WASTE WATER PLANTCourse descriptionIn this course you will learn the maintenance /operation of the waste water plant in the paint shop.

ContentTechnical basics » Waste water treatment process, waste water treatment stages

Chemical basics » Acids and alkalis » Difference between separation, flocculation and coagulation

Filtration » Separation and filtration technologies






» Basic functions » Operation modes » Central start on /off

» Adjust parameters for dosing » Selector switches on visualization » Local operation elements


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LEVEL 2

MAI

NTE

NAN

CE &

OPE

RAT

ION


Requirements: Level 1 – Dürr Plant Basics A.01 / Level 2 – Paint Booth & Air Supply Units

Course number: B.08 a Duration: 1.5 Days Course number: B.08 b Duration: 0.5 Days

AIR POLLUTION CONTROL – Ecopure® CRC & Ecopure® TAR Course descriptionIn this course you will learn the maintenance /operation of the air pollution control system Ecopure® CRC with Ecopure® TAR.

Content System overviewFunction principle, task of the Ecopure® CRC and Ecopure® TAR in a paint shop, physical basics of VOC-concentrator

Components Structure of the Ecopure® CRC (explanation of rotor and drive components), structure of the Ecopure® TAR (explanation of burner and gas regulation components)

Function and operation modesDetails of the different functions (e.g. temperature control) and operation modes (e.g. heating, rinsing)

» Structure of the technical documentation » Maintenance tasks and cleaning intervals according to maintenance list (e.g. maintenance of Ecopure® TAR and VOC-concentrator)



» Operation concept (basic functions of the visualization)


» Basic functions » Automatic mode / manual mode » Operation modes on visualization

» Adjust parameters to optimize performance » Local operation elements

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LEVEL 2

MAI

NTE

NAN

CE &

OPE

RAT

ION

Maintenance course Operation course


CONVEYORCourse descriptionIn this course the conveyor elements of a paint shop are explained. You will learn the components, layout and material flow chart as well as the maintenance /operation of the system.Using the technical documentation you will be able to define maintenance and lubrication intervals, change spare and wear parts as well as maintain /operate the plant safely.

ContentCourse basics » Overview of conveyor types in a paint shop » Plant designation system for conveyors » Sensor concept and sensor types for car body transportation – moving sensors, fixed sensor, initiators » Material flow chart and conveyor layout – process of a car body through a paint shop – from body shop to final assembly » Conveyor elements and their special functions

» Structure of the technical documentation » Service drawings » Maintenance tasks and lubrication intervals according to maintenance and lubrication list

» Practical exercises for the exchange of spare parts of certain conveyor elements according to repair and mounting instructions

» Special topics: Automatic lubrication systems » Controls concept of the plant with control panels and visualization stations

» Safety instructions for maintenance procedures » Operation concept (basic functions of the operation panels and local operation buttons)

» Safety instructions for operation » Operation concept (basic functions and advanced settings of the visualization and operation panels)

» Local operation buttons » Operation modes (manual mode, automatic mode, setup mode)

» Troubleshooting » Alarm message lists

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LEVEL 2

MAI

NTE

NAN

CE &

OPE

RAT

ION

Maintenance course Operation course


RoDip® M / RoDip® ECourse descriptionIn this course you will learn the maintenance /operation of the RoDip® M / RoDip® E conveyor system.

ContentCourse basics » Basic function of RoDip® system, different types of RoDip®

» Layout of pretreatment and electrocoating plant » Steps of dipping process » Dipping curves

Components and functions » Components of carrier, skid types, components of entry and exit station, drive units » RoDip® M / RoDip® E specific components

» Structure of the technical documentation » Service drawings » Maintenance tasks and intervals according to components installed and maintenance list

» Practical exercises for the exchange of spare parts and wear parts

» Manual and automatic lubrication » Control cabinets of the plant » Safety instructions for maintenance » Operation concept (basic functions of the operation panels and local operation buttons)

» Safety instructions for operation » Operation concept (basic functions and advanced settings of the visualization and operation panels)

» Local operation buttons » Operation modes (manual mode, automatic mode, setup mode)

» Troubleshooting

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LEVEL 2

CON

TROL

SYS

TEM

S

CONTROL SYSTEMS – BASICS Course description In this course you will learn the control systems basics of process and conveyor technique in the paint shop. General basics of control systems as well as specific functions and function blocks of the Dürr Basic Software (DBS) will be explained. Related to the DBS you will learn the designation system of the plant, the relation between mechanical and electrical components and the interface between plant PLCs and the visualization system.

ContentSystem overview » Basics of the respective PLC system » Plant overview and material flow chart » Plant numbering system » Controls concept of the plant (network, central and decentral control systems)

Dürr Basic Software (DBS) » Task and benefit of a software standard » Structure of the DBS (software architecture and program structure)

Basic functions of the DBS » Programming and parameterization of the main function blocks (e.g. controller module, step sequences, drive module) » Programming of manual and automatic mode » Alarm modules » Safety program » Interface to the visualization system

Practical exercises – programming of DBS function blocks

Requirements: Level 1 – Dürr Plant Basics A.01 / Basic knowledge of the respective PLC system (TIA, Step 7, Rockwell)

Duration: 3 Days

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LEVEL 3

CON

TROL

SYS

TEM

S

16

Course number: C.02 / Duration: 1 Day each PLC

Requirements: Level 2 – Control systems Basics – C.01

PROCESS PLCs – HARDWARE & SOFTWARECourse descriptionIn this course you will learn the plant specific hardware and software of the process PLCs, such as pretreatment, electrocoating or ovens. A specific course is considered for each PLC in the paint shop.

Content » Basic structure and function groups of the plant » Hardware overview (control cabinets, main cabinet, decentral control elements, plant numbering system) » PLC program of the plant » Hardware configuration » Step sequences and operation modes » Selector switches » Interlocks to other external and internal systems » Safety PLC program » Software controller, e.g. temperature or level control (parameters, controller modules, program flow, controller commissioning)

» Visualization system (e.g. status windows, operation elements) » Practical exercises – error simulation

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LEVEL 3

CON

TROL

SYS

TEM

S

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Course number: C.03 / Duration: 2 – 3 Days (depending on quantity of PLCs)

Requirements: Level 2 – Control systems Basics – C.01

CONVEYOR PLCs – HARDWARE & SOFTWARECourse descriptionIn this course you will learn the plant specific hardware and software of the conveyor PLCs. For RoDip®M / RoDip®E a specific course is considered.

Content » Hardware overview (control cabinets, main cabinet, decentral control elements, control desks, plant numbering system) » Controls concept (central and decentral elements, communication, network) » System configuration » Configuration and parameterization of drive elements, e.g. motors, frequency inverters » PLC program structure for conveyor elements » Standard function modules » Operation modes (manual mode, automatic mode, setup mode) » Step sequences » Selector switches » Interfaces to supervisory control system and visualization » Conveyor interlocks to process and application technology » Safety PLC program » Fault analysis and record of alarm messages » Visualization system (e.g. status windows, operation elements) » Practical exercises – error simulation » Car body tracking

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LEVEL 4

CON

TROL

SYS

TEM

S

EcoDC MACS – HARDWARE & SOFTWARECourse descriptionIn this course you will learn the function, operation and setting of the rectifier system EcoDC MACS. You will be able to create profiles and change parameters for the coating of car bodies.

Content » Basics of bus systems, signal exchange technologies and IGBT modules » System overview of electrocoating plant and rectifier » Structure of hardware (control cabinets, wiring diagrams) » Structure and function of system components: Dialysis cells, busbar, coupling thyristor, cooling system » Voltage program setting » Rectifier profile setting » Special functions (e.g. car body tracking, type detection) » PLC program of the plant » Safety installations » Interlocks to other plants » Status windows of visualization » Maintenance instructions (change IGBT module, maintenance of cooling system etc.) » Practical exercises – error simulation

Course number: C.04 / Duration: 2 Days

Requirements: Level 2 – Control systems Basics – C.01 / Level 3 – Electrocoating – Hardware & Software – C.02

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LEVEL 4

CON

TROL

SYS

TEM

S

RoDip®M/E – HARDWARE & SOFTWARECourse descriptionIn this course you will learn the hardware and software of the RoDip® M/E plant. Starting with structure and function of the RoDip® system, the PLC program, operation and troubleshooting will be explained.

Content » System overview – function of RoDip®, components, skid transfer » Plant hardware – control cabinets, wiring diagram » PLC program – plant specific function blocks » Fault and alarm processing » Signal exchanges » Safety PLC » Status windows of visualization » Manual and automatic mode » Emergency stop » Practical exercises – error simulation

RoDip®E specific topics » Track elements and areas » Virtual positions » Hardware of carrier » Program setting – setting for routes, car bodies, parameters

Course number: C.05 / Duration: 2 Days

Requirements: Level 2 – Control systems Basics – C.01 / Level 3 – Conveyor – Hardware & Software – C.03

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LEVEL 3

VISU

ALIZ

ATIO

N S

YSTE

MS

EcoScreen – ADMINISTRATORCourse descriptionIn this course you will learn the administration of the plant visualization for process and conveyor technique in the paint shop. The course contains detailed information about the system architecture, background processes, data bases and the connection of the visualization to the process and conveyor PLCs.

ContentSystem overview » System architecture (front end, back end) » Communication » Data bases

Installation of the system » Data structure » System requirements » Browser settings

Components and services of the system » IO manager » Alarm server and trend server » Additional services (e.g. event server, security manager, language manager, system manager)

Practical exercises » Installation and setting of the visualization » Maintenance and updates of the system » Generation of PC backup » Recovery of the system in case of emergency

Requirements: Level 2 – Control systems – Basics C.01

Duration: 3 Days

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LEVEL 4

VISU

ALIZ

ATIO

N S

YSTE

MS

EcoScreen ENGINEERINGCourse descriptionIn this course you will learn how to create and change the HMI for process and conveyor technique. The course contains detailed information about the VisuStudio and powerpoint tools.

ContentIntroduction » Installation of EMOS.Web » Installation of PPT tools » Overview of VisuStudio

Functions » Create animations (blinking, swapping colours, dynamic text) » Linking of pages » Use of drawing tools » Use of library elements (create and update library elements) » Alarms (addition of alarm tags, animation of alarms) » Property editor » Rotation and position animation

Practical exercises » Add new symbol to HMI » Update data base » Animation of symbols

Requirements: Level 2 – C.01 Control systems – Basics / Level 3 – D.01 EcoScreen Admin

Duration: 2 Days

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CONDITIONS OF REGISTRATION AND PARTICIPATIONRegistrationRegistrations, confirmations and appointments must be made in writing. The number of participants is limited to 6 people per course.

Course feeThe prices indicated at the time of registration are applicable for the course fee. These are net prices per course plus statutory value added tax and are to be paid at the end of the training. Travel and accommodation expenses as well as the costs of local transfers are not included in the course price.

Cancellation A course registration must be canceled in writing. Cancellation up to 3 weeks before the course begins is free of charge. Cancellation up to 2 weeks before the course begins will be charged at 50 % of the course price; cancellation made after that time as well as no-shows are charged at 100 % of the course price. However, a replacement participant may be nominated.

Abandonment/absenceWe will inform you immediately if a course has to be abandoned or cannot be completed due to the absence of a trainer or for important reasons for which Dürr is not responsible. At the same time, we will propose an alternative date. However, this shall not give right to any further claims.

AccommodationPlease let us know if we can assist you with making your hotel reservation. Please note that all liabilities in respect of the hotel must be settled by the course participants and/or the participants’ company.

Right of modificationWe reserve the right to adapt the training contents to reflect the state of the art or the respective training needs. Special attention is drawn in this regard to the entry requirements specified in the respective course programs.

Safety regulationsThe course participants are required to abide by the applicable safety and accident avoidance regulations. If personal protective equipment is a requirement of participation, this must be brought along by the participants and worn during the training.

Exclusion of liabilityThe information in the training courses and in the training documents is imparted by us to the best of our knowledge and in good conscience. However, we are unable to accept any liability for any errors in the technical information that is conveyed in the training courses either verbally or in writing, or contained in the training documents or data carriers provided. Neither are we able to accept any liability for any damage or sub sequential damage resulting from such errors.

CopyrightDuplication of the training documents for unauthorized purposes or the forwarding, utilization and communication of its contents to third parties is prohibited. The same applies to documents or programs provided on data carriers. The software provided for training purposes must not be removed, modified, copied in part or used in any other unauthorized manner.

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Dürr – Leading in Production EfficiencyFive divisions, one goal: maximum production efficiency for our customers

» Paint and Final Assembly Systems: paint shops and final assembly systems for the automotive industry » Application Technology: robot technologies for the automatic application of paint as well as sealants and adhesives » Clean Technology Systems: air pollution control, noise abatement systems and battery coating lines » Measuring and Process Systems: balancing systems as well as assembly, testing and filling technology » Woodworking Machinery and Systems: machinery and systems for the woodworking industry

Documents

DÜRR TRAINING · Relation between paint booth and paint separation system as well as the basic structure of the paint separation system EcoDryScrubber Components and function Paint