Gema OptiFlex 2 B, Operating Instructions Manual

Page 1: ...En Translation of the original operating instructions Operating instructions and spare parts list Manual coating equipment OptiFlex 2 B ...

Page 2: ...oduct names are trademarks or registered trademarks of their respective holders Reference is made in this manual to different trademarks or registered trademarks Such references do not mean that the manufacturers concerned approve of or are bound in any form by this manual We have endeavored to retain the preferred spelling of the trademarks and registered trademarks of the copyright holders To th...

Page 3: ...the OptiFlow IG06 injector 13 Air flow rates 13 Electrical data 13 Pneumatic data 14 Dimensions 14 Processible powders 14 Design and function 15 General view 15 Scope of delivery 16 OptiFlex 2 B 16 Typical properties Characteristics of the functions 16 Processing the powder directly from the original powder manufacturer s container 16 Freely rotating head piece 16 Start up 17 Preparation for start...

Page 4: ... Cleaning the fluidizing suction unit 34 Cleaning the OptiFlex 2 GM03 manual powder gun 34 Maintenance and cleaning of the filter unit 35 Replacing the filter element 35 Troubleshooting 37 General information 37 Spare parts list 39 Ordering spare parts 39 OptiFlex 2 B manual coating equipment Spare parts 40 OptiFlex 2 B manual coating equipment Spare parts 41 OptiFlex 2 B Pneumatic group 42 ...

Page 5: ...eration Safety symbols pictograms The following warnings with their meanings can be found in the Gema operating instructions The general safety precautions must also be followed as well as the regulations in the operating instructions DANGER Danger due to live electricity or moving parts Possible consequences death or serious injury WARNING Improper use of the equipment could damage the machine or...

Page 6: ...evention regulations as well as other generally recognized safety regulations occupational health and structural regulations are to be observed Furthermore the country specific safety regulations also must be observed Additional safety and operation notices can be found on the accompanying CD or on the homepage www gemapowdercoating com Start up is forbidden until it has been established that the ...

Page 7: ...f the booth stops the powder coating device must switch off too The control units for the spray guns must be installed and used in zone 22 Spray guns are allowed in zone 21 Only original Gema OEM parts are guaranteed to maintain the explosion protection rating If damages occur related to the use of spare parts from other manufacturers all relevant warranty or compensation claims are void Condition...

Page 8: ...ted regularly when starting work The condition of the work piece attachments as well as the hangers must guarantee that the work pieces remain grounded The appropriate measuring devices must be kept ready in the workplace in order to check the grounding The floor of the coating area must conduct electricity normal concrete is generally conductive The supplied grounding cable green yellow must be c...

Page 9: ...quipment and the mains should only be removed when the power supply is switched off As far as it is necessary the operating firm must ensure that the operating personnel wear protective clothing e g facemasks A dust mask corresponding to filter class FFP2 at minimum must be worn during any cleaning work The operating personnel must wear electrically conductive steel toe footwear e g leather soles ...

Page 10: ...n established that the OptiFlex 2 B manual coating equipment has been installed and wired according to the EU Machinery Directive 2006 42 EC EN 60204 1 machine safety must also be observed 5 Unauthorized modifications to the OptiFlex 2 B manual coating equipment exempt the manufacturer from any liability from resulting damage 6 The relevant accident prevention regulations as well as other generall...

Page 11: ...ptiFlex 2 B manual coating equipment It will safely guide you through the start up process and give you references and tips for the optimal use of your new powder coating system Information about the functionality of the individual system components booth gun control unit manual gun or powder injector should be referenced to their enclosed corresponding documents ...

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Page 13: ...The manufacturer is not responsible for any incorrect use and any associated risks are assumed by the user alone For a better understanding of the interrelationships in powder coating it is recommended that the operating instructions for all other components be read as well so as to be familiar with their functions too OptiFlex 2 B manual coating equipment Utilization The electrostatic OptiFlex 2 ...

Page 14: ...data Connectable guns OptiFlex 2 B connectable OptiFlex 2 GM03 yes Warning The OptiFlex 2 B manual coating equipment can only be used with the specified gun type Powder output guide values General conditions for the OptiFlow Injector Powder type Epoxy polyester Powder hose length m 6 Powder hose Ø mm 10 Powder hose type POE with guide strips Input pressure bar 5 5 Conveying air nozzle Ø mm 1 6 Cor...

Page 15: ...lex 2 B Range Factory setting Flow rate fluidizing air OptiFlex B 0 1 0 Nm h 0 1 Nm h Electrode rinsing air flow rate 0 3 0 Nm h 0 1 Nm h Flow rate total air at 5 5 bar 1 8 6 5 Nm h Note The total air consumption for the device is determined based on the 3 configured air values These values apply for an internal control pressure of 5 5 bar Electrical data OptiFlex 2 B Nominal input voltage 100 240...

Page 16: ...n pressure regulator setting 5 5 bar 80 psi Max water vapor content of the compressed air 1 3 g m Max oil vapor content of the compressed air 0 1 mg m Max compressed air consumption 8 Nm h Dimensions OptiFlex 2 B Width 460 mm Depth 862 mm Height 1105 mm Weight 42 kg Processible powders OptiFlex 2 B Plastic powder yes Metallic powder yes Enamel powder no ...

Page 17: ...er wheel 7 Powder box 16 Swivel wheel 8 Swivel arm with guide sleeve OptiFlex 2 GM03 manual powder gun All information about the OptiFlex 2 CM03 manual powder gun can be found in the documentation for that equipment enclosed with this manual OptiFlex 2 CG09 control unit All information about the OptiFlex 2 CG09 manual gun control unit can found in the documentation for that equipment enclosed with...

Page 18: ...red supplementary air black fluidizing air black and rinsing air black Operating manual Short instructions Typical properties Characteristics of the functions Processing the powder directly from the original powder manufacturer s container The OptiFlex 2 B manual coating equipment allows for powder to be processed directly out of the original powder manufacturer s container A titled vibrating floo...

Page 19: ...rresponding power and compressed air supply available Powder preparation and powder quality Set up The OptiFlex 2 B manual coating equipment should always be set up vertically on a flat surface WARNING The manual coating equipment must not under any circumstances be set up near a heat source such as an enameling furnace or an electromagnetic source such as a control cabinet If the manual equipment...

Page 20: ...rt up OptiFlex 2 B Mounting instructions The OptiFlex 2 B manual coating equipment must be set up in accordance with the setup and connecting instructions included with delivery Manual coating equipment OptiFlex 2 B ...

Page 21: ... with the setup and connection instructions Please also review the operating instructions for the OptiFlex 2 CG09 manual gun control unit 1 2 Note Use clamp to connect grounding cable to the cabin or the suspension arrangement Check ground connections with Ohm meter and ensure 1 MOhm or less Maintenance unit Injector Gun PowerClean module Fluidizing suction unit ...

Page 22: ...V 03 13 20 Start up OptiFlex 2 B 3 4 5 6 7 8 9 10 Note The compressed air must be free of oil and water ...

Page 23: ...shooting guide as well as the gun control unit operating manual Note The remainder of the start up procedure for the OptiFlex 2 GM03 manual powder gun is explicitly described in the operating instructions for the OptiFlex 2 CG09 manual powder gun control unit chapter Initial start up and Daily start up ...

Page 24: ...red as a integral component of an OptiFlex apparatus then the system parameters will have been factory preconfigured for optimal use For more on this please also see the operating instructions for the OptiFlex 2 CG09 manual gun control unit NOTE The manual gun control unit always starts up to the last configured settings ...

Page 25: ...the ON key The displays illuminate and the control unit is ready for operation 2 Swivel aside the fluidizing suction unit 3 Place the open powder container on the vibrating table WARNING If a container is placed on the vibrating plate then fingers caught in the gap between the two plates can be crushed The container may weight a max of 30 kg 4 Place the fluidizing suction unit onto the powder 5 Se...

Page 26: ...tal air 4 0 Nm h High voltage 80 kV Spray current 80 μA Electrode rinsing air 0 1 Nm h Fluidizing air 0 1 Nm h for OptiFlex B and S 8 Setting the total air volume correct powder cloud too little total air Note A total air volume of 4 Nm h and a 50 powder share are recommended as the base values 9 Adjust the powder output volume e g according to the desired coating thickness or much powder little p...

Page 27: ...wn b too much electrode rinsing air 11 Setting the fluidization a Press the key The second display level will be shown b c Check the powder fluidization in the powder container The powder fluidization in the powder containers depends on the powder characteristics the humidity and the ambient air temperature Fluidizing and vibration start by switching on the control unit WARNING If the fluidization...

Page 28: ...on the CG09 display Note The PowerClean function can be stopped as required using the P key b Procedure Effect automatic The automatic rinsing process is started Injector powder hose gun and spray nozzle are purged using compressed air The automated PowerClean function enables parallel cleaning of other components such as the fluid intake unit powder container etc manual The operator controls the ...

Page 29: ...V 03 13 OptiFlex 2 B Initial start up 27 Setting the background illumination 1 Press key The display switches to the following level 2 Select the desired brightness ...

Page 30: ...When a color change takes place the individual components of the manual coating equipment must be cleaned carefully All powder particles of the former color must be removed during this process The following describes an extreme color change light to dark 1 2 3 4 5 6 7 8 9 10 ...

Page 31: ...V 03 13 OptiFlex 2 B Initial start up 29 11 12 13 14 15 16 16 17 18 19 20 21 22 23 Remove and clean the nozzle purge gun using air ...

Page 32: ...V 03 13 30 Initial start up OptiFlex 2 B 24 25 26 27 28 29 30 31 32 33 34 ...

Page 33: ...he control unit Note The adjustments for high voltage powder output electrode rinsing air and fluidizing remain stored If in disuse for several days 1 Separate from power mains 2 Clean the coating equipment see the corresponding operating manual 3 Turn off the compressed air main supply ...

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Page 35: ...ual of the OptiFlow injector 2 Clean the powder gun For more on this please also review the user manual for the OptiFlex 2 GM03 manual powder gun 3 Clean the powder hose Please also review the section Color change Weekly maintenance 1 Clean fluidizing suction unit injector rinsing module and powder gun The fluidizing suction unit is placed back into the powder shortly before restarting operation 2...

Page 36: ... FFP2 at minimum must be worn during any cleaning work Cleaning the fluidizing suction unit 1 Remove the injector 2 Remove rinsing module 3 Remove the fluidizing suction unit 4 Clean the fluidizing suction unit with compressed air Also blow off the suction tube with compressed air 5 Clean the injector see therefore the injector user manual 6 Clean rinsing module 7 Reassemble the individual parts C...

Page 37: ...ex 2 GM03 manual powder gun Maintenance and cleaning of the filter unit The filter unit on the OptiFlex B manual coating equipment measures and cleans the compressed air This is where the equipment s main compressed air connection is located Replacing the filter element Procedure 1 Unscrew the filter glass on the filter unit 2 Loose the cap screw 3 Remove the complete filter element 4 Replace the ...

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Page 39: ...l Gema representative The gun does not spray powder although the control unit is switched on and the gun trigger is pressed Compressed air not present Connect the equipment to the compressed air Injector throttle motor or nozzle on injector powder hose or powder gun are clogged Clean the corresponding part Insert sleeve in the injector is clogged Replace Insert sleeve is not installed Mount insert...

Page 40: ...dized Compressed air not present Connect the equipment to the compressed air Fluidizing air is set too low on the control unit Set the fluidizing air correctly Throttle motor defective Contact local Gema representative No electrode rinsing air Rinsing air throttle motor defective Contact local Gema representative Vibrator not functioning Vibrator condenser broken Contact local Gema representative ...

Page 41: ...mp Ø 18 15 mm When ordering cable or hose material the required length must also be given The spare part numbers for this kind of bulk stock is always marked with an Wearing parts are always marked with a All dimensions of plastic hoses are specified with the external and internal diameter Example Ø 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d WARNING Only original Gema spare parts sh...

Page 42: ... mm 201 316 5 3 Plastic tube Ø 8 6 mm black 1008 038 6 Rinsing module complete See operating instructions OptiFlex 2 GM03 manual powder gun 1007 362 7 Pneumatic connection for PowerClean air complete incl Pos 7 1 and 7 2 7 1 Quick release connection NW5 Ø 8 mm 1008 027 7 2 Plastic tube Ø 8 6 mm black 103 152 8 Fluidizing suction unit complete 1007 509 9 Pneumatic connection for fluidizing air comp...

Page 43: ...V 03 13 OptiFlex 2 B Spare parts list 41 OptiFlex 2 B manual coating equipment Spare parts OptiFlex 2 B manual coating equipment Spare parts 10 14 16 15 12 13 2 1 3 11 6 8 5 4 9 7 ...

Page 44: ...V 03 13 42 Spare parts list OptiFlex 2 B OptiFlex 2 B Pneumatic group Pneumatic group complete 1007 120 1 Filter cartridge 20 μm 1007 325 OptiFlex 2 B Pneumatic group 1 ...

Page 45: ...V 03 13 OptiFlex 2 B Spare parts list 43 ...