FLYDRY

FlYDrY

technical Data

Measures and dataFlydry 3000 code:Flydry 3000 column size:

Flydry 3000 column and overhead crane weight:

Flydry 3500 code:Flydry 3500 column size:


Flydry 4000 code:Flydry 4000 column size:


Flydry Fixstation code:

Overhead crane width:

Overhead crane length:

Time for installation:Warranty:

2100min 2,70 mt

max 3,10 mt

120 kg

2101min 3,10 mtmax 3,60 mt

135 kg

2102min 3,10 mtmax 3,60 mt

150 kg

2110

min 3,70 mtmax 4,00 mtmin 4,00 mtmax 7,00 mt

h 2412 months

Flydry is perfect for both mid and high volume body shops of all types and sizes: this is the versatile, incredibly effective system that fits anyone’s needs. It can be used for filling and priming as well as for painting, so as to free up the furnace booth.One Flydry can serve up to four workstations, and a preparer can perform up to three times as many prep jobs as he would with a conventional system. The Flydry column swivels through 360° to dry all sides of the vehicle.The lamp arm rotates through 180° to cover the entire vehicle profile in the vertical or horizontal direc-tion. Movements during the drying process and to and from different areas are performed automatically.

min 8.8 ftmax 48.2 ft

264 lb

min 10.1 ftmax 11.8 ft

297 lb

min 10.1 ft max 11.8 ft

330 lb

min 12.1 max 13.1 ft

min 13.1max 22.9 ft

Overhead crane

Rails

The Flydry overhead crane carries the robotised column and slides along three parallel aluminium rails that span across the whole width of the prep-aration area to carry out the drying cycle.The overhead crane is made up of:Two side carriages and a central motor-driven car-riage that slide along the aluminium rails.Double aluminium rails connect the three carriag-es to form the overhead crane that provides the sliding movement of the robotised column.

Each Flydry module features three aluminium rails - two side rails and a central one - that span across the width of the preparation area. In a configura-tion with several modules, the rails will be butted up to one another.

Movement and work rangeThe robotised column can slide to any position along the length and width of the preparation area while drying. This means the vehicle or the parts to be dried can be placed in any position.

Robotised columnThe robotised column slides independently within the overhead crane along the length of the preparation area and the overhead crane slides across the width of the area.The robotised column can rotate through 360° about its axis to dry all sides of the vehicle.The robotised column is equipped with a pneumatically controlled arm that carries and orients the lamp unit as re-quired by the job. The lamp unit features 2 lamps - one at the bottom and one at the top - each equipped with a LTC (Laser Temperature Control) sensor for dynamic temperature monitoring during the drying process.The control console including display and keyboard is located on the robotised column.

Orientation and positioning of robotised lamp column

Version with standard, mid sized an tall column

The robotised column can rotate through 360° about its axis and can be set in any position to dry the four sides of the vehicle. It features two pneumatic drive units to set the lamp arm at the required height and angle.The drive units allow Flydry to move the two lamps from a fully vertical to a fully horizontal position and set them at varying angles. This way, the two lamps can be set in the ideal position parallel to vehicle surface for flawless drying.

Flydry can be equipped with 3 different robotised columns to suit the height of the preparation area.

GasNo. of lamps:Size of lamps:Power output:Hourly consumption - LPG (G31)at 12 mbar:Hourly consumption - Natural gas(G20) at 12 mbar:Power consumption duringpreheating (3’:30” only):Catalyser life: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

Control BoxElectronic board:Keyboard:Display:Installed power input during first 3’:30” after power-on:Supply voltage:Frequency:Controls voltage:

Compressed airLine pressure:Pipe size connection:

Control Box

Motors

15.7 x 29.5”

1.43 lb/h

2.8 lb/h

2400x750 mm

11 kW

0,65 kg/h

1,1 cu.m./h

1,45 kW5000 h. - 30000 drying cycles

22 kW

1,3 Kg/h

2,2 cu.m./h

20/25 mbar

12 mbar1”G

microcontrollermembrane

2 x 20 DIGIT

2,9 kW230 V~

50/60 Hz24 V~

8 bar8x10 ØixØe mm

The DrytronicPlus lamp can run on LPG or natural gas with no difference in performance.The gas unit is installed outside the booth or prep-aration area and includes 1 main solenoid valve, 1 NC (Normally Closed) solenoid valve and a safety pressure valve that maintains proper pressure.Gas is never present inside the booth or prepara-tion area where the Flydry is installed, because it is only delivered to the lamps when drying is ac-tivated. Connection to customer’s plant mains isensured 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.

The electrical panel is located outside the booth, on the right or left side, and accommodates safety devices, counters and the transformer.

The drive motors are ATEX - certified 24V DC motors equipped with ENCODERS for continuous position control.

Keyboard and display

Monitoring and control system

Controls are located on the robotised column. Fly-dry is equipped with a membrane keyboard and a two-line display to allow for data management by operator.

The electrical panel on the robotised column ac-commodates a board with microcontroller that manages motor with encoder, software, I/O sig-nals and all other components.

Laser temperature control sensorFlydry features a laser sensor for dynamic temperature detection on the 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.

Approval and QualityApproval: EU: CE - ATEX II 3 G X

Au: Compliant to Australian safety standardsAS/NZS 4114.1:2003 – AS 3814.1:2009

US: cETLus Listed - Intertek 5000803

LOOK AT THE FUTURE

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 triggersan emergency condition whenever it detects an abnormal event or depletion.

Lamp unitFlydry features a unit with two independent lamps that can operate individually or two at a time during treatment. The lamp unit is equipped with an automatic LTC (Laser Temperature Control) system that monitors drying and ad-justs 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 devel-oped at the Symach research laboratories, that controls all formula parameters associated with sensors and Flydry automation system.

Software

Work travel setting

Lamp selection

Treatment start

Treatment started screen

Drying formula selection and editing

a) Manual controls (overhead crane movements and column movements in four directions).b) Treatment size (start/end of treatment).c) Lamp selection (bottom and/or top lamp).d) Drying formulas (selected from database).e) Drying temperature.f) System stop (switch off when work is finished).

Operator can choose to enter travel lengths ranging from 0.5 m up to the length of the vehicle or part to be dried.

Operator can choose to use the bottom lamp or both lamps for drying.

When the operator has finished painting, pressing the “Start” key starts the drying treatment in automatic mode.

The treatment-started window displays the temperature reading of the LTC (Laser Temperature Control) system, so operator can monitor the job on hand continuously. The exact progress of the treatment under way is also displayed.

After entering treatment size and selecting the lamp or lamps to be used, the operator chooses the drying formula from a database.A formula is a set of parameters and the work cycle which the robots performs automatically to dry a specific paint product, a given portion of a vehicle or of loose parts.Formula parameters can be edited in the screen before pressing “start”.This function allows operator to edit 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:Temperature, for special jobs or when drying materials with special requirements.Speed, for harder or softer drying depending on coat thickness, among other things.Passes, number of passes can be modified for special drying cycles.Formula database entry and editing.The operator can edit or enter customised formulas, also according to their preferences or technique.

saFetY Devices

System stop

Language

DryingControl

The two DryingControl functions

Flydry has a main switch to stop the system and an emergency stop switch. When the system remains unused for half an hour, automatic switch-off is activated.

The Flydry software offers many display languages to choose from. Display language can be selected during the con-figuration procedure and all messages and indications will be displayed in the selected language.

Flydry 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 Temperature 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 asrequired 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

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 or in the preparation area, 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 or in the preparation area features double-tier safety, with a first NC (nor-mally-closed) main and three additional NC solenoid valves - one for each lamp unit - that are only activated when the drying treatment is active.

Special pipes

Alarm devices

Gas and solvent detector

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 or in the preparation area 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 or preparation area to monitor the internal environment at all times and detect any traces of gas during operation.

Catalyser control

Thermostat

Air pressure valve

Motor drive effort control

Control hardware and software

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

A thermostat is installed inside the booth or preparation area to check for proper internal temperature.

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

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.

accessories

Rail moduleCode:Aluminium section rails:Aluminium section shelves:Belt tensioner mountings.Time for installation:

Anchorage omega kitCode:Plenum or ModulLight clamps.

Leg-beam kit Tubular leg:

Tubular beam:Tubular beam:Time for installation:

1° coat

Final coat

Drying

Drying

21804000 mm x 3 pieces4000 mm x 1 piece

8 h

2181

3000 or 4000 mm

3000 mm4000 mm

4 h

157.4” x 3 pieces157.4” x 1 piece

2182 code2183 code

118.11” or 157.4”118.11”

157.4”

applications: boDY Filler

1

3

2

4

2:00 minutes

3:00 minutes

2:00 minutes

fly

dr

yf

ly

dr

y

1:00 minute

TOTAL TIME 8:00 minutes

applications: primer

applications: water base

fly

dr

yf

ly

dr

yf

ly

dr

yf

ly

dr

y

TOTAL TIME 9:00 minutes

1° coat

Drying

Drying

Drying

2° Coat

3° Coat

1

2

4

6

3

5

1:00 minute

2:00 minutes

2:00 minutes

2:00 minutes

1:00 minute

1:00 minute

ppg - basf - akzo Nobel

Drying

1

2 1:30 minutes

1° + 2° Coat (without flash off) 2:00 minutes

applications: clear coatf

ly

dr

yf

ly

dr

yf

ly

dr

y

Drying

TOTAL TIME

3

41:30 minutes

6:00 minutes

3° Coat (Drop coat)1:00 minutes

aXalta

Drying

TOTAL TIME

1

21:30 minutes

4:30 minutes

1° + 2° + 3° Drop coat(without flash off) 3:00 minutes

Drying

TOTAL TIME

1

22:00 minutes

6:00 minutes

1° + 2° Coat(without flash off) 4:00 minutes

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

[email protected]

Ph. +39 (0)51 963161

Documents

FLYDRY