Gema OptiFlex 2 V, Operating Instructions And Spare Parts List

Page 1: ...En Translation of the original operating instructions Operating instructions and spare parts list Fresh powder system OptiFlex 2 V ...

Page 2: ...r product 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 con cerned approve of or are bound in any form by this manual We have en deavored to retain the preferred spelling of the trademarks and registered trademarks of the copyright holders...

Page 3: ...w Injector IG06 12 Air flow rates 12 Electrical data 13 Dimensions 13 Processible powders 13 Design and function 14 Overall view 14 Scope of delivery 14 OptiFlex 2 V 14 Optional accessories for OptiFlex 2 V 15 Typical characteristics properties of the functions 15 Processing the powder directly from the original powder manufacturer s container 15 Start up 17 Preparation for start up 17 Basic condi...

Page 4: ...s 27 Powder hose rinsing 27 Cleaning 28 Cleaning the fluidizing suction unit 28 Troubleshooting 29 General information 29 Spare parts list 31 Ordering spare parts 31 OptiFlex 2 V fresh powder system Spare parts list 32 OptiFlex 2 V fresh powder system Spare parts list 33 ...

Page 5: ...bols pictograms The following contains a list of warnings with their meanings found in the Gema operating instructions Apart from the regulations in the relevant operating instructions the general safety precautions must also be fol lowed DANGER danger due to live electricity or moving parts Possible consequences Death or serious injury ATTENTION improper use of the equipment could damage the mach...

Page 6: ...ther generally recognized safety regulations occupational health and structural regula tions are to be observed Furthermore the country specific safety regulations also must be ob served Additional safety and operation notices can be found on the accompany ing CD or on the homepage www gemapowdercoating com Start up is forbidden until it has been established that the OptiFlex 2 V fresh powder syst...

Page 7: ... If 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 by using spare parts from other manu facturers the warranty or compensation claim is void Conditions leading to dangerou...

Page 8: ... be checked tested 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 y...

Page 9: ...ld 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 or N95 at minimum must be worn during any cleaning work The operating personnel must wear electrically conductive steel toe footwear e g leather soles The operating person...

Page 10: ...en established that the OptiFlex 2 V has been set up and wired according to the guidelines for machinery 2006 42 EG EN 60204 1 machine safety must also be observed 5 Unauthorized modifications to the OptiFlex 2 V fresh powder sys tem exempt the manufacturer from any liability from resulting damage 6 The relevant accident prevention regulations as well as other generally recognized safety regulatio...

Page 11: ...and tips for the optimal use of your new powder coating system Information about the function mode of the individual system components booth gun control unit manual gun or powder injector can be found in the supplied documents NOTE These operating instructions describe all the features and functions of the fresh powder system that were available at the time this oper ating instructions went to pre...

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Page 13: ... associated with such actions 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 V Fresh powder system Utilization The fresh powder system is ideally suited for the powder supply for one or two manual o...

Page 14: ... hose Ø mm 10 Type of powder hose POE with guide strips Input pressure bar 5 5 Conveying air nozzle mm 1 6 Correction value C0 Powder output zeroing adjust ment Guide values for OptiStar with OptiFlow Injector IG06 All values in these tables are guide values Differing environmental condi tions wear and different powder types can affect the table values Total air 3 Nm h 4 Nm h 5 Nm h Powder output ...

Page 15: ... 110 230 VAC max 100 W Frequency 50 60 Hz Temperature range 0 C 40 C 32 F 104 F Max surface temperature 120 C 248 F Approvals II 3 D IP54 120 C Dimensions OptiFlex 2 V Width 460 mm Depth 862 mm Height 900 mm Weight 32 kg Processible powders OptiFlex 2 V Plastic powder yes Metallic powder yes Enamel powder no ...

Page 16: ... Frame 4 Vibrating table 8 Hose holder OptiFlow injector All information about the OptiFlow injector will be found in the correspond ing enclosed documentation Scope of delivery OptiFlex 2 V Mobile frame with hose holder vibrating base and a fluidizing suction unit plug in OptiFlow injector Pneumatic hoses for conveying air red supplementary air black and fluidizing air black Operating manual Shor...

Page 17: ...onveying air red and fluidizing air black Typical characteristics properties of the functions Processing the powder directly from the original powder manufacturer s container The OptiFlex 2 V fresh powder system allows for powder to be processed directly out of the original powder manufacturer s container A titled vibrat ing floor has been included to ensure that the powder container empties itsel...

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Page 19: ...sideration fresh powder system is set up properly corresponding power supply available device grounded properly Powder preparation and powder quality Set up The OptiFlex 2 V fresh powder system should always be set up vertically on a flat surface WARNING The fresh powder system must not under any circumstances be set up near a heat source such as an enameling furnace or an elec tromagnetic source ...

Page 20: ...V 03 13 18 Start up OptiFlex 2 V Assembly guide The OptiFlex 2 V fresh powder system must be set up in accordance with the following setup and connecting instructions OptiFlex 2 V Fresh powder system ...

Page 21: ...ew Note Use clamp to connect grounding cable to the cabin or the suspen sion arrangement Check ground connections with Ohm meter and ensure 1 MOhm or less Note The compressed air must be free of oil and water Maintenance unit Injector Gun PowerClean module Fluidizing suction unit 5 5 bar ...

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Page 23: ...V 03 13 OptiFlex 2 V Initial start up 21 Initial start up Note If a malfunction occurs see section Troubleshooting Grounding Power tension supply ...

Page 24: ...tainer 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 Setting the fluidization guide value 0 1 Nm h a Check the powder fluidization in the powder container The powder fluidization in the powder containers ...

Page 25: ...n When a color change takes place the individual components of the fresh powder system must be cleaned carefully All powder particles of the for mer 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 26: ...V 03 13 24 Initial start up OptiFlex 2 V 11 12 13 14 15 16 17 18 19 20 21 ...

Page 27: ...nitial start up 25 Shutdown 1 Switch off the vibrator If in disuse for several days 1 Separate from power mains 2 Clean the coating equipment see the corresponding operat ing manual 3 Turn off the compressed air main supply ...

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Page 29: ... Weekly maintenance 1 Clean the fluidizing suction unit with compressed air Place the fluidizing suction unit back into the powder shortly before restart ing operation 2 Check the control unit grounding connections to the coating booth the suspension devices of the work pieces or the convey or chain If in disuse for several days 1 Separate from power mains 2 Clean the Fresh powder system 3 Turn of...

Page 30: ...ilation system must be turned on for all cleaning work A dust mask corresponding to filter class FFP2 or N95 at minimum must be worn during any cleaning work Cleaning the fluidizing suction unit 1 Remove the injector 2 Remove the fluidizing suction unit 3 Clean the fluidizing suction unit with compressed air Also blow off the suction tube with compressed air 4 Clean the injector see therefore the ...

Page 31: ... injector is worn Check with the plug gauge and replace if necessary Insert sleeve in the injector is clogged Clean the corre sponding part Insert sleeve is not installed Mount insert sleeve Fluidization not run ning see below The powder is not fluidized Compressed air not present Connect the equip ment to the com pressed air Fluidizing air adjust ment is set too low Set the fluidizing air correct...

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Page 33: ... Clamp Ø 18 15 mm When ordering cable or hose material the required length must also be given The spare part numbers of this 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 ATTENTION Only original Gema spare parts shoul...

Page 34: ... 5 1 5 2 and 5 3 5 1 Quick release connection NW5 Ø 8 mm black 261 637 5 2 Nut with kink protection M12x1 mm Ø 8 mm 201 316 5 3 Plastic tube Ø 8 6 mm black 1008 038 8 Fluidizing suction unit complete 1007 509 9 Pneumatic connection for Fluidizing air complete incl pos 9 1 9 2 and 9 3 9 1 Quick release connection NW5 Ø 6 mm 200 840 9 2 Nut with kink protection M10x1 mm Ø 6 mm 201 308 9 3 Plastic tu...

Page 35: ...V 03 13 OptiFlex 2 V Spare parts list 33 OptiFlex 2 V fresh powder system Spare parts list OptiFlex 2 V fresh powder system Spare parts 14 16 15 12 13 3 8 5 9 4 ...

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