ITW Gema OptiFlex, Operating Instructions And Spare Parts List

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

Page 2: ... 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 regis tered trademarks of the copyright holders To the best of our knowledge...

Page 3: ...nd regulations 8 Product specific security measures 10 About this manual 11 General information 11 Function description 13 Field of application 13 Typical characteristics 13 OptiFlex B manual coating equipment 14 Structure 14 OptiStar control unit 14 OptiFlow injector 15 Scope of delivery 15 OptiFlex B 1 15 Additional supply for OptiFlex B 2 15 Technical data 17 OptiFlex B manual coating equipment...

Page 4: ...ptiSelect manual powder gun 24 Maintenance and cleaning of the filter unit 25 Replacing the filter element 25 Troubleshooting guide 27 General information 27 Schematic diagrams 29 Block diagram OptiFlex B 29 Pneumatic diagram OptiFlex B 30 Spare parts list 31 Ordering spare parts 31 OptiFlex B manual coating equipment spare parts list 32 OptiFlex B manual coating equipment spare parts list 33 Opti...

Page 5: ...ious injury WARNING Improper use of the equipment could damage the machine or cause it to malfunction Possible consequences minor injuries or damage to equip ment INFORMATION Useful tips and other information Conformity of use 1 The OptiFlex B manual coating equipment is built to the latest specification and conforms to the recognized technical safety regulations It is designed for the normal appl...

Page 6: ... electrostat ic powder spraying equipment General information The powder spraying equipment from ITW Gema is designed with safety in mind and is built according to the latest technological specifications This equipment can be dangerous if it is not used for its specified pur pose Consequently it should be noted that there exists a danger to life and limb of the user or third party a danger of dama...

Page 7: ...esponsible for the safe operation of equipment ITW Gema is in no way responsible for any resulting damages Safety conscious working Each person responsible for the assembly start up operation service and repair of powder spraying equipment must have read and unders tood the operating instructions and the Safety regulations chapter The operator must ensure that the user has had the appropriate trai...

Page 8: ... instructions and checks in and around the powder spraying equipment 8 No safety devices should be dismantled or put out of operation If the dismantling of a safety device for set up repair or servicing is necessary reassembly of the safety devices must take place immediately after the maintenance or repair work is finished The powder spraying device must be turned off while servicing is car ried ...

Page 9: ...irm must ensure that local conditions are met when re pairs are made to the electronic parts or when the equipment is restarted so that there are additional measures such as barriers to prevent unau thorized access Prohibition of unauthorized conversions and modifica tions to machines All unauthorized conversions and modifications to electrostatic spraying equipment are forbidden for safety reason...

Page 10: ...es The manufacturers instructions must be ob served when using such cleaning agents 12 The manufacturers instructions and the applicable environmental requirements must be observed when disposing of powder lac quer and cleaning agents 13 If any part of the spray gun is damaged broken parts tears or missing then it should not be used 14 For your own safety only use accessories and attachments liste...

Page 11: ...static hand held spraying equipment 2 EN 50 053 part 2 Requirements for the selection installation and use of electrostatic spraying equipment for flammable mate rials Hand held electrostatic powder spray guns 2 EN 50 177 Stationary electrostatic spraying equipment for flamma ble coating powder 2 PR EN 12981 Coating plants Spray booths for application of organic powder coating material Safety requ...

Page 12: ... 2 B 1000 Bruxelles or the appro priate national committee 4 VDE Verlag GmbH Bismarckstrasse 33 1000 Berlin 12 Product specific security measures The installation work to be done by the customer must be carried out according to local regulations Before starting up the plant a check must be made that no foreign objects are in the booth or in the ducting input and exhaust air It must be observed tha...

Page 13: ...r the working with the OptiFlex 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 function mode of the individual system components reciprocators booths powder gun controls powder guns etc should be referenced to their corresponding documents ...

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Page 15: ...for any damage resulting from this the risk for this is assumed by the user alone The OptiFlex B electrostatic powder manual coating equipment with the OptiSelect manual powder gun is ideally suited for manual coating of ob jects in small series Typical characteristics Processing the powder directly from the original powder manufacturer s container Total emptying of the powder container due to inc...

Page 16: ...tiSelect manual powder gun 11 Gun holder 3 OptiFlow injector 12 Hose holder 4 Frame with hand rail 13 Hose connections 5 Fluidizing suction unit 14 Shelf 6 Vibrating base 15 Rubber wheel 7 Powder box 16 Swivel wheel 8 Swivel arm with guide sleeve OptiStar control unit All information about the OptiStar control unit you will find in the corres ponding enclosed manual 4 13 3 8 1 5 7 16 6 11 2 12 10 ...

Page 17: ...fore the OptiSelect manual powder gun user manual Pneumatic hoses for conveying air red supplementary air black and fluidizing air black Additional supply for OptiFlex B 2 An additional OptiStar control unit complete with gun holder special powder supply cable and connecting ma terial A second fluidizing suction unit with plug in OptiFlow in jector a double arm a pneumatic kit and screw joints An ...

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Page 19: ...e range 0 40 C Approvals Pneumatical data OptiFlex B manual coating equipment Compressed air main connection G1 4 internal thread Max input pressure 10 bar Min input pressure 6 bar Max water vapor content of compressed air 1 3 g m Max oil vapor content of compressed air 0 1 mg m Max compressed air consumption 8 m h Connectable guns OptiFlex B manual coating equipment connectable OptiSelect GM02 ye...

Page 20: ...tiFlex B manual coating equipment Attention The OptiFlex B manual coating equipment may be used only with the specified gun types Dimensions OptiFlex B manual coating equipment Width 690 mm Depth 800 mm Height 1135 mm Weight 58 kg ...

Page 21: ...th or the conveyor Check ground connections with Ohm meter and ensure 1 MOhm or less 4 Connect the gun cable plug to the socket 2 3 on the rear side of the control unit 5 Connect the rinsing air hose to the electrode rinsing air out put 1 4 and to the powder gun 6 Attach the injector connect the powder hose to the injector and to the powder gun 7 Connect the red hose for conveying air to the corre...

Page 22: ...ble 3 Place the fluidizing suction unit onto the powder Switching on the booth The coating booth is switched on according to the corresponding user manual Start up Switch on the control unit 1 Press the power switch ON The displays illuminate and the control unit is ready for operation Note The further start up procedure for the OptiFlex B manual coating equipment gun is explicitly described in th...

Page 23: ...izing suction unit 2 Clean the powder hose Strip the powder hose from the hose connection on the injector Point the gun into the booth Blow through the hose manually with a compressed air gun Fit the powder hose again to the hose connection on the injector 3 Dismantle and clean the powder gun see therefore the user ma nual of the OptiSelect manual powder gun 4 Clean the injector see therefore the ...

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Page 25: ...zing suction unit injector and powder gun Just place the fluidizing suction unit in the powder shortly before restarting operation 2 Check the control unit grounding connections to the coating booth the suspension devices of the work pieces or the con veyor chain If in disuse for several days 1 Disconnect the mains plug 2 Clean the coating equipment 3 Turn off the compressed air main supply Powder...

Page 26: ...o guarantee the coating quality Note Before cleaning the powder gun switch off its control unit The compressed air used for cleaning must be free from oil and water Daily 1 Blow off the outside of the gun and wipe clean etc Weekly 2 Remove the powder hose from the connection 3 Remove the spray nozzle from the gun and clean it 4 Blow through the gun with compressed air beginning from the connection...

Page 27: ... coating equipment measures and cleans the compressed air Here the main compressed air connection of the equipment 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 29: ...lve coil Rinsing air solenoid valve of round jet nozzle defective Replace valve coil Gun plug gun cable or gun cable connection defective Replace corresponding part or send in for repair Gun LED remains dark although the gun trigger is operated Gun plug gun cable or gun cable connection defective Remote control on powder gun defective Replace corresponding part or send in for repair Replace remote...

Page 30: ...e Connect the equipment to the compressed air Set the fluidizing air cor rectly Replace the motor throt tle The gun does not spray powder al though the control unit is switched on and the gun trigger is operated Compressed air not present Injector motor throttle or nozzle on injector powder hose or powder gun are clogged Nozzle in the injector is clogged Nozzle is not inserted Fluidizing not runni...

Page 31: ...V 05 10 OptiFlex B manual coating equipment Schematic diagrams 29 Schematic diagrams Block diagram OptiFlex B Block diagram OptiFlex B ...

Page 32: ...uf 5 5 bar einstellen bei Luftverbrauch 6 Nm 3 h 1 1 1 5 1 4 1 3 1 2 Fluidluft M1 M1 M1 Fluid Ansaug Einheit E1 M1 Motordrossel E1 Eingangseinheit M1 24V 0 3 Pneumatic diagram OptiFlex B Adjust to 5 5 bar by 6 Nm h air consumption Supplementary air Conveying air Fluidizing air Fluidizing suction unit M1 Motor throttle E1 Input unit Electrode rinsing air 3 10 l min ...

Page 33: ... 203 386 1 piece Clamp Ø 18 15 mm When ordering cable or hose material the required length must also be given The spare part numbers of this yard meter ware is always marked with an The wear parts are always marked with a All dimensions of plastic hoses are specified with the external and inter nal diameter Example Ø 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d WARNING Only original I...

Page 34: ... Cable connection fitting for vibrator cable M16 1 6 10 5 mm brass not shown 265 780 17 Cable plug 4 pins male 206 466 18 Countersunk Allen screw M6x30 mm 1002 952 19 Grounding cable complete 301 140 20 Plastic hose Ø 8 6 mm 103 756 21 Vibrator motor 220 240 VAC 50 Hz 1001 748 Vibrator motor 120 VAC 389 382 22 IG02 V Injector complete see corresponding user manual 23 Gun retainer 1003 076 24 Spare...

Page 35: ...manual coating equipment spare parts list 29 Filter unit complete see corresponding spare parts list 30 Snap ring A 25 237 094 Please indicate length OptiFlex B manual coating equipment spare parts list 9 19 27 13 2 10 12 11 3 1 17 22 21 7 8 4 25 5 6 26 24 23 18 30 29 28 14 20 ...

Page 36: ...zel Ø 0 3 mm 338 303 7 Elbow 1 8 a 1 8 a 235 733 8 Plug NW5 1 8 i 200 859 9 Fluidizing pad 1 8 a 237 264 10 Cable sleeve Ø 4 8 1 5 mm 265 276 11 Retaining bracket 1002 054 A Pneumatic connection fluidizing air complete incl pos 12 13 and 14 1002 041 12 Quick release connection NW5 Ø 6 mm 200 840 13 Nut with kink protection M10x1 mm Ø 6 mm 201 308 14 Plastic hose Ø 6 4 mm black 1001 973 15 Swivel a...

Page 37: ...07 321 2 T piece 1 4 i 1 4 a 1 4 i 262 064 3 Elbow joint 1 4 3xØ 8 8 mm 1007 327 7 Filter cartridge 20 µm 1007 325 9 Manometer G1 4 0 10 bar 1007 328 10 Rectus nipple NW 7 4 1 4 a 256 730 11 Grommet Ø 8 mm 238 023 12 Elbow joint 1 4 i 1 4 a 222 674 14 Rectus quick release connection for pos 10 NW 7 8 Ø 10 mm 239 267 OptiFlex B filter unit 9 2 3 11 10 12 7 14 1 11 ...