ITW Gema OptiFlex 2 B, Operating Instructions And Spare Parts List

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

Page 2: ...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 the best of our kn...

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 32 Cleaning the OptiFlex 2 GM03 manual powder gun 32 Maintenance and cleaning of the filter unit 33 Replacing the filter element 33 Troubleshooting 35 General information 35 Spare parts list 37 Ordering spare parts 37 OptiFlex 2 B manual coating equipment Spare parts 38 OptiFlex 2 B manual coating equipment Spare parts 39 OptiFlex 2 B Pneumatic group 40 ...

Page 5: ...ation Safety symbols pictograms The following warnings with their meanings can be found in the ITW 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 ...

Page 6: ...revention 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 itwgema ch Start up is forbidden until it has been established that the OptiFlex 2...

Page 7: ...witched on until the booth is in operation 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 ITW 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 wa...

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: ...ir The plug connections between the powder spraying equipment 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 The operating personnel must wear electrically conductive footwear e g leather soles The operating personnel should hold the gun with bare...

Page 10: ...lished 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 exempts the manufacturer from any liability from resulting damage 6 The relevant accident prevention regulations as well as other generally reco...

Page 11: ...BOptiFlex 2 B en doc 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: ...pe must be configured For more on this please see the operating instructions for the OptiFlex 2 CG09 manual gun control unit The Tribo gun the gun is not type approved ATEX Only for enamel powder the gun is not type approved ATEX Warning The OptiFlex 2 B manual coating equipment can only be used with the specified gun types Powder output guide values General conditions for the OptiFlow Injector Po...

Page 15: ...ptiFlex 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...

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: ...is set up properly Gun control unit correctly connected Gun correctly connected Corresponding 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 furn...

Page 20: ...V 05 11 18 Start 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 ...

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 05 11 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: ...arameters 6 Press the application button for the appropriate preset mode flat parts complicated parts overcoat The arrow above the desired button lights up OR 7 Press program key a Select desired program 01 20 b Change coating parameters as required Note Programs 01 20 are preset at the factory but can be modified at any time after which they are automatically stored Description Presetting Powder ...

Page 26: ...thickness or much powder little powder Note To achieve maximum efficiency we recommend avoided an overly high powder volume where possible Für den Anfang empfiehlt sich die Standardeinstellung von 50 und eine Gesamtluftmenge von 4 Nm h Die Gesamtluftmenge wird dabei automatisch von der Steuerung konstant gehalten If values are entered that the equipment cannot implement then the operator is inform...

Page 27: ...dizing and vibration start by switching on the control unit 12 Point the gun into the booth not at the object to be coated press the gun trigger and visually check the powder output 13 Check whether everything is functioning correctly 14 Coating 15 Adjust the coating parameters as necessary 16 Activate the rinsing function periodically Note It prevents the bridging phenomena that can lead to short...

Page 28: ...owerClean function enables parallel cleaning of other components such as the fluid intake unit powder container etc manual The operator controls the number and length of the PowerClean impulse by pressing the pistol trigger a second time After completion of the PowerClean procedure the controller switches back to coating mode Setting the background illumination 1 Press key The display switches to ...

Page 29: ...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 30: ...V 05 11 28 Initial start up OptiFlex 2 B 11 12 13 14 15 16 16 17 18 19 20 21 22 23 Remove and clean the nozzle purge gun using air ...

Page 31: ...V 05 11 OptiFlex 2 B Initial start up 29 24 25 26 27 28 29 30 31 32 33 34 ...

Page 32: ...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 ...

Page 33: ...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 34: ... with compressed air 5 Clean the injector see therefore the injector user manual 6 Clean rinsing module 7 Reassemble the individual parts Cleaning the OptiFlex 2 GM03 manual powder gun Frequent cleaning of the gun helps to guarantee the coating quality Note Before cleaning the powder gun switch off the control unit The compressed air used for cleaning must be free of oil and water Daily 1 Blow off...

Page 35: ...it 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 filter element 5 Clean the filter glass on the inside and install it again ...

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Page 37: ...er 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 sleeve Fluidization not running see below Total ...

Page 38: ...pment 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 Vibrator not plugged in plug in Incorrect equipme...

Page 39: ... 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 ITW Gema spare parts sh...

Page 40: ...ions OptiFlex 2 GM03 manual powder gun 1007 362 7 Pneumatic connection for conveying air complete incl Pos 7 1 and 7 2 1008 032 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 conveying air complete incl Pos 9 1 9 2 and 9 3 1008 031 9 1 Quick release connection NW5 Ø 6 mm 200 840 9 2 Nut...

Page 41: ...V 05 11 OptiFlex 2 B Spare parts list 39 OptiFlex 2 B manual coating equipment Spare parts OptiFlex 2 B manual coating equipment Spare parts 15 10 14 17 16 12 13 2 1 3 11 6 8 5 4 9 7 ...

Page 42: ...V 05 11 40 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 43: ...V 05 11 OptiFlex 2 B Spare parts list 41 ...