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

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

Page 2: ...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 the best of ou...

Page 3: ... rates 12 Electrical data 13 Pneumatic data 13 Dimensions 13 Processible powders 13 Design and function 14 General view 14 Scope of delivery 15 OptiFlex 2 C 15 Typical properties Characteristics of the functions 15 Processing the powder from the application cup 15 Start up 17 Preparation for start up 17 Basic conditions 17 Set up 17 Mounting instructions 18 Connection instructions 18 Initial start...

Page 4: ... the OptiFlex 2 GM03 manual powder gun 30 Maintenance and cleaning of the filter unit 31 Replacing the filter element 31 Troubleshooting 33 General information 33 Spare parts list 35 Ordering spare parts 35 OptiFlex 2 C manual coating equipment Spare Parts List 36 OptiFlex 2 C manual coating equipment Spare Parts 37 OptiFlex 2 C Pneumatic group 38 ...

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: ...ll 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 C manual coating equipment...

Page 7: ...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 warranty or compensation claims are void Conditions leadin...

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: ...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 The operating personnel...

Page 10: ...lished that the OptiFlex 2 C 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 C manual coating equipment exempt the manufacturer from any liability from resulting damage 6 The relevant accident prevention regulations as well as other generally recog...

Page 11: ...COptiFlex 2 C 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 ...

Page 12: ......

Page 13: ...nufacturer is not responsible for any incorrect use and the risks 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 C Manual coating equipment Utilization The electrostatic...

Page 14: ... only be used with the specified gun type Air flow rates The total air consists of conveying air and supplementary air in relation to the selected powder quantity in As a result the total air volume is maintained constant OptiFlex 2 C Range Factory setting Flow rate fluidizing air OptiFlex C 0 5 0 Nm h 1 0 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 ...

Page 15: ...ax surface temperature 100 C 212 F Approvals II 3 D IP54 100 C Pneumatic data OptiFlex 2 C Max input pressure 10 bar Min input pressure 6 bar Input pressure Dynamic based on 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 11 Nm h Dimensions OptiFlex 2 C Width 444 mm D...

Page 16: ...M03 manual powder gun All information about the OptiFlex 2 GM03 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 this manual Application cup All information about the application cup will be fo...

Page 17: ...on to the control unit OptiFlex 2 GM03 manual powder gun with gun cable powder hose rinsing air hose and standard nozzle set For more on this see the operating manual for the OptiFlex 2 GM03 manual powder gun Operating manual Short instructions Typical properties Characteristics of the functions Processing the powder from the application cup The OptiFlex 2 C manual coating equipment processes powd...

Page 18: ......

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 C 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 fur...

Page 20: ...ions included with delivery OptiFlex 2 C Manual coating equipment Connection instructions Connection instructions overview The OptiFlex 2 C manual coating equipment must be connected in accordance with the setup and connection instructions Please also review the operating instructions for the OptiFlex 2 CG09 manual gun control unit Filter unit Gun Application cup ...

Page 21: ...p 19 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 3 4 5 6 7 8 9 10 Note The compressed air must be free of oil and water ...

Page 22: ......

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: ...tegral 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: ...t with the ON key The displays illuminate and the control unit is ready for operation 2 Fill in the desired powder quantity in the application cup 3 Carefully place the dip tube into the powder in order to avoid the clogging of the dip tube 4 Lock the bayonet closure 5 Set coating parameters 6 Press the application button for the appropriate preset mode flat parts complicated parts overcoat The ar...

Page 26: ...lectrode rinsing air 0 1 Nm h Fluidizing air 0 0 Nm h for OptiFlex C 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 powder ...

Page 27: ... that the equipment cannot implement then the operator is informed of this by a blinking in the relevant display and a temporary error message 10 Setting the electrode rinsing air a Press the key The second display level will be shown b too much electrode rinsing air 11 Point the gun into the booth not at the object to be coated press the gun trigger and visually check the powder output 12 Check w...

Page 28: ...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 1 Clean the application cup see therefore the application cup user manual 2 Dismantle and clean the powder gun see therefore the user manual of the Manual powder gun 3 Prepare the manual coating equipment with new powder...

Page 29: ... the 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 coating apparatus see Chapter on Cleaning and maintenance 3 Turn off the compressed air main supply ...

Page 30: ......

Page 31: ...g spare parts list Daily maintenance 1 Clean the application cup see therefore the application cup user manual 2 Clean the powder gun For more on this please also review the user manual for the OptiFlex 2 GM03 manual powder gun Weekly maintenance 1 Clean the gun and the application cup 2 Check the control unit grounding connections to the coating booth the suspension devices of the work pieces or ...

Page 32: ... with solvents or other fluidities 1 Empty any powder out of the application cup 2 Clean the gun and the outside of the application cup by blowing off wiping etc 3 Release the bayonet closure between cup cover and cup 4 Clean the cup 5 Pull out the dip tube and clean it 6 If necessary activate the den PowerClean mode see also the gun operating instructions 7 Clean the cup with compressed air 8 Cle...

Page 33: ...review the user manual for the OptiFlex 2 GM03 manual powder gun Maintenance and cleaning of the filter unit The filter unit on the OptiFlex 2 C 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...

Page 34: ......

Page 35: ...e fuse Power pack defective Contact local 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 Throttle motor or powder gun are clogged Clean the corresponding part The application cup is not correctly or not connected at all to the control unit Check the pneu...

Page 36: ...iciently grounded Check grounding reground at better quality High voltage and current deactivated Press the selection key application key High voltage cascade defective Contact local Gema representative Irregular powder output Poor closure Dismantle the application cup completely check the O rings and replace them if necessary Pneumatic hoses not correctly connected Check the connections and conne...

Page 37: ...amp 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 WARNING Only original ITW Gema spare parts should...

Page 38: ...645 4 2 Nut with kink protection M12x1 mm Ø 8 mm 201 316 4 3 Plastic tube Ø 8 6 mm red 103 500 5 Pneumatic connection for supplementary air complete incl Pos 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 6 Nut M10x1 Ø 6 mm 263 052 7 Screw cap Ø 6 mm 263 044 10 Pneumatic group compl...

Page 39: ...V 06 11 OptiFlex 2 C Spare parts list 37 OptiFlex 2 C manual coating equipment Spare Parts OptiFlex 2 C manual coating equipment Spare Parts 15 2 1 10 3 5 16 6 13 4 11 7 ...

Page 40: ...V 06 11 38 Spare parts list OptiFlex 2 C OptiFlex 2 C Pneumatic group Pneumatic group complete 1007 120 1 Filter cartridge 20 µm 1007 325 OptiFlex 2 C Pneumatic group 1 ...

Page 41: ...V 06 11 OptiFlex 2 C Spare parts list 39 ...