OptiFlex S manual coating equipment - spare parts

OptiFlex S manual coating equipment - spare parts
En
Operating instructions and spare parts list
OptiFlex S
Manual coating equipment
Translation of the original operating instructions
V 05/10
Documentation OptiFlex S manual coating equipment
© Copyright 2006 ITW Gema GmbH
All rights reserved.
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translated, stored on a retrieval system or transmitted in any form or by
any means for any purpose, neither as a whole nor partially, without the
express written consent of ITW Gema GmbH.
OptiTronic, OptiGun, EasyTronic, EasySelect, OptiFlow and SuperCorona are registered trademarks of ITW Gema GmbH.
OptiMatic, OptiMove, OptiMaster, OptiPlus, MultiTronic and Gematic are
trademarks of ITW Gema GmbH.
All other 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 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 knowledge and belief, the information contained in this
publication was correct and valid on the date of issue. ITW Gema GmbH
makes no representations or warranties with respect to the contents or
use of this publication, and reserves the right to revise this publication
and make changes to its content without prior notice.
Printed in Switzerland
ITW Gema GmbH
Mövenstrasse 17
9015 St. Gallen
Switzerland
Phone: +41-71-313 83 00
Fax.: +41-71-313 83 83
E-Mail: [email protected]
Homepage: www.itwgema.ch
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Table of contents
General safety regulations
3 Safety symbols (pictograms)................................................................................... 3 Conformity of use .................................................................................................... 3 Technical safety regulations for stationary electrostatic powder spraying
equipment ............................................................................................................... 4 General information ................................................................................... 4 Safety conscious working .......................................................................... 5 Individual safety regulations for the operating firm and/or operating
personnel ................................................................................................... 5 Notes on special types of hazard ............................................................... 6 Safety requirements for electrostatic powder coating ................................ 7 A summary of the rules and 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 S manual coating equipment .................................................................. 14 Structure................................................................................................... 14 OptiStar control unit ................................................................................. 14 OptiFlow injector ...................................................................................... 14 Stirrer recipient ......................................................................................... 15 Scope of delivery .................................................................................................. 16 OptiFlex 1-S ............................................................................................. 16 Additional supply for OptiFlex 2-S ........................................................... 16 Technical Data
17 OptiFlex S manual coating equipment .................................................................. 17 Electrical Data .......................................................................................... 17 Pneumatical Data ..................................................................................... 17 Connectable guns .................................................................................... 17 Dimensions .............................................................................................. 18 Start-up and operation
19 Connecting guide .................................................................................................. 19 Preparation for start-up ......................................................................................... 20 Fill the stirrer recipient with powder ......................................................... 20 Switching on the booth............................................................................. 20 Start-up ................................................................................................................. 20 Stirrer ....................................................................................................... 20 Switch on the control unit ......................................................................... 21 OptiFlex S manual coating equipment
Table of contents  1
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Color change
23 General information .............................................................................................. 23 Maintenance and cleaning
25 Daily maintenance ................................................................................................ 25 Weekly maintenance ............................................................................................ 25 If in disuse for several days .................................................................................. 25 Powder hose rinsing ................................................................................ 25 Cleaning................................................................................................................ 26 Cleaning the OptiSelect manual powder gun .......................................... 26 Maintenance and cleaning of the filter unit ........................................................... 26 Replacing the filter element ..................................................................... 26 Fault elimination
27 General information .............................................................................................. 27 Schematic diagrams
29 Block diagram - OptiFlex S ................................................................................... 29 Pneumatic diagram - OptiFlex S........................................................................... 30 Spare parts list
31 Ordering spare parts............................................................................................. 31 OptiFlex S manual coating equipment - spare parts list ....................................... 32 OptiFlex S manual coating equipment - spare parts ............................................ 33 OptiFlex S - stirrer recipient .................................................................................. 34 OptiFlex S - stirrer recipient .................................................................................. 35 OptiFlex S - stirrer drive unit ................................................................................. 36 OptiFlex S - stirrer drive unit ................................................................................. 37 OptiFlex S - filter unit ............................................................................................ 38 2  Table of contents
OptiFlex S manual coating equipment
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General safety regulations
This chapter sets out the fundamental safety regulations that must be followed by the user and third parties using the OptiFlex S manual coating
equipment.
These safety regulations must be read and understood before the OptiFlex S manual coating equipment is used.
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 or cause it to
malfunction. Possible consequences: minor injuries or damage to equipment
INFORMATION!
Useful tips and other information
Conformity of use
1. The OptiFlex S manual coating equipment is built to the latest
specification and conforms to the recognized technical safety
regulations. It is designed for the normal application of powder
coating.
2. Any other use is considered as non-conform. The manufacturer
is not responsible for damage resulting from improper use of this
equipment; the end-user alone is responsible. If the OptiFlex S
manual coating equipment is to be used for other purposes or
other substances outside of our guidelines then ITW Gema
GmbH should be consulted.
3. Observance of the operating, service and maintenance instructions specified by the manufacturer is also part of conformity of
OptiFlex S manual coating equipment
General safety regulations  3
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use. The OptiFlex S manual coating equipment should only be
used, maintained and started up by trained personnel, who are
informed about and are familiar with the possible hazards involved.
4. Start-up (i.e. the execution of a particular operation) is forbidden
until it has been established that the OptiFlex S manual coating
equipment has been set up and wired according to the guidelines
for machinery (98/37 EG). EN 60204-1 (machine safety) must also be observed.
5. Unauthorized modifications to OptiFlex S manual coating equipment exempts the manufacturer from any liability from resulting
damage.
6. The relevant accident prevention regulations, as well as other
generally recognized safety regulations, occupational health and
structural regulations are to be observed.
7. Furthermore the country-specific safety regulations must be observed.
Explosion protection
0102
II (2) D
Protection type
Temperature class
IP54
T6 (zone 21)
T4 (zone 22)
Technical safety regulations for stationary electrostatic 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 purpose. Consequently it should be noted that there exists a danger to life
and limb of the user or third party, a danger of damage to the equipment
and other machinery belonging to the user and a hazard to the efficient
operation of the equipment.
1. The powder spraying equipment should only be started up and
used once the operating instructions have been carefully studied.
Improper use of the controlling device can lead to accidents, malfunction or damage to the control itself.
2. Before every start-up check the equipment for operational safety
(regular servicing is essential)!
3. Safety regulations BGI 764 and VDE regulations DIN VDE 0147,
Part 1, must be observed for safe operation.
4. Safety precautions specified by local legislation must be observed.
5. The plug must be disconnected before the machine is opened for
repair.
6. The plug and socket connection between the powder spraying
equipment and the mains network should only be taken out when
the power is switched off.
4  General safety regulations
OptiFlex S manual coating equipment
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7. The connecting cable between the controlling device and the
spray gun must be set up so that it cannot be damaged during
operation. Safety precautions specified by local legislation must
be observed!
8. Only original ITW-Gema spare parts should be used, because
the explosion protection will also be preserved that way. Damage
caused by other parts is not covered by guarantee.
9. If ITW-Gema powder spraying equipment is used in conjunction
with machinery from other manufacturers then their safety regulations must also be taken into account.
10. Before starting work familiarize yourself with all installations and
operating elements, as well as with their functions! Familiarization during operation is too late!
11. Caution must be exercised when working with a powder/air mixture! A powder/air mixture in the right concentration is flammable!
Smoking is forbidden in the entire plant area!
12. As a general rule for all powder spraying installations, persons
with pacemakers should never enter high voltage areas or areas
with electromagnetic fields. Persons with pacemakers should not
enter areas with powder spraying installations!
WARNING!
We emphasize that the customer himself is responsible 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 understood the operating instructions and the “Safety regulations”-chapter. The
operator must ensure that the user has had the appropriate training for
powder spraying equipment and is aware of the possible sources of danger.
The control devices for the spray guns must only be set up and used in
zone 22. Only the spray gun should be used in zone 21.
The powder spraying equipment should only be used by trained and authorized personnel. This applies to modifications to the electrical equipment, which should only be carried out by a specialist.
The operating instructions and the necessary closing down procedures
must be followed before any work is carried out concerning the set-up,
start-up, operation, modification, operating conditions, mode of operation,
servicing, inspection or repairs.
The powder spray equipment can be turned off by using the main switch
or failing that, the emergency shut-down. Individual components can be
turned off during operation by using the appropriate switches.
Individual safety regulations for the operating
firm and/or operating personnel
1. Any operating method which will negatively influence the technical safety of the powder spraying equipment is to be avoided.
OptiFlex S manual coating equipment
General safety regulations  5
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2. The operator should care about no non-authorized personnel
works on the powder spraying equipment (e.g. this also includes
using the equipment for non-conform work).
3. For dangerous materials, the employer has to provide an operating instructions manual for specifying the dangers arising for humans and environment by handling dangerous materials, as well
as the necessary preventive measures and behavior rules. The
operating instructions manual has to be written in an understandable form and in the language of the persons employed, and
has to be announced in a suitable place in the working area.
4. The operator is under obligation to check the powder spraying
equipment at least once every shift for signs of external damage,
defects or changes (including the operating characteristics)
which could influence safety and to report them immediately.
5. The operator is obliged to check that the powder spraying
equipment is only operated when in satisfactory condition.
6. As far as it is necessary, the operating firm must ensure that the
operating personnel wear protective clothing (e.g. facemasks).
7. The operating firm must guarantee cleanliness and an overview
of the workplace with suitable 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 carried out. The operator must train and commit the responsible
personnel to this.
9. Activities such as checking powder fluidization or checking the
high-voltage spray gun etc. must be carried out with the powder
spraying equipment switched on.
Notes on special types of hazard
Power
It is necessary to refer once more to the danger of life from high-voltage
current if the shut-down procedures are not observed. High voltage
equipment must not be opened - the plug must first be taken out - otherwise there is danger of electric shock.
Powder
Powder/air mixtures can be ignited by sparks. There must be sufficient
ventilation in the powder coating booth. Powder lying on the floor around
the powder spraying device is a potentially dangerous source of slipping.
Static charges
Static charges can have the following consequences: Charges to people,
electric shocks, sparking. Charging of objects must be avoided - see
"Earthing".
Grounding/Earthing
All electricity conducting parts and machinery found in the workplace (according to DIN VDE 0745, part 102) must be earthed 1.5 meters either
6  General safety regulations
OptiFlex S manual coating equipment
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side and 2.5 meters around each booth opening. The earthing resistance
must amount to maximally 1 MOhm. The resistance must be tested on a
regular basis. The condition of the machinery surroundings as well as the
suspension gear must ensure that the machinery remains earthed. If the
earthing of the machinery includes the suspension arrangements, then
these must constantly be kept clean in order to guarantee the necessary
conductivity. The appropriate measuring devices must be kept ready in
the workplace in order to check the earthing.
Compressed air
When there are longer pauses or stand-still times between working, the
powder spraying equipment should be drained of compressed air. There
is a danger of injury when pneumatic hoses are damaged and from the
uncontrolled release and improper use of compressed air.
Crushing and cutting
During operation, moving parts may automatically start to move in the
operating area. It must be ensured that only instructed and trained personnel go near these parts. The operator should ensure that barriers
comply with the local security regulations.
Access under exceptional circumstances
The operating firm must ensure that local conditions are met when repairs are made to the electronic parts or when the equipment is restarted
so that there are additional measures such as barriers to prevent unauthorized access.
Prohibition of unauthorized conversions and modifications to machines
All unauthorized conversions and modifications to electrostatic spraying
equipment are forbidden for safety reasons.
The powder spraying equipment should not be used if damaged, the faulty part must be immediately replaced or repaired. Only original ITWGema replacement parts should be used. Damage caused by other parts
is not covered by guarantee.
Repairs must only be carried out by specialists or in ITW-Gema workshops. Unauthorized conversions and modifications may lead to injury or
damage to machinery. The ITW Gema GmbH guarantee would no longer
be valid.
Safety requirements for electrostatic powder
coating
1. This equipment is dangerous if the instructions in this operating
manual are not followed.
2. All electrostatic conductive parts, in particular the machinery
within 5 meters of the coating equipment, must be earthed.
3. The floor of the coating area must conduct electricity (normal
concrete is generally conductive).
4. The operating personnel must wear electricity conducting footwear (e.g. leather soles).
5. The operating personnel should hold the gun with bare hands. If
gloves are worn, these must also conduct electricity.
OptiFlex S manual coating equipment
General safety regulations  7
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6. The supplied earthing cable (green/yellow) must be connected to
the earthing screw of the electrostatic powder spraying hand appliance. The earthing cable must have a good metallic connection with the coating booth, the recovery unit and the conveyor
chain and with the suspension arrangement of the objects.
7. The electricity and powder supply to the hand guns must be set
up so that they are fully protected against heat and chemical
damage.
8. The powder coating device may only be switched on once the
booth has been started up. If the booth cuts out then the powder
coating device must be switched off.
9. The earthing of all electricity conducting devices (e.g. hooks,
conveyor chains) must be checked on a weekly basis. The earthing resistance must amount to maximally 1 MOhm.
10. The control device must be switched off if the hand gun is
cleaned or the nozzle is changed.
11. When working with cleaning agents there may be a risk of hazardous fumes. The manufacturers instructions must be observed when using such cleaning agents.
12. The manufacturers instructions and the applicable environmental
requirements must be observed when disposing of powder lacquer 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 listed
in the operating instructions. The use of other parts can lead to
risk of injury. Only original ITW-Gema replacement parts should
be used.
15. Repairs must only be carried out by specialists and under no circumstances should they be carried out in the operating area. The
former protection must not be reduced.
16. Conditions leading to dangerous levels of dust concentration in
the powder spraying booths or in the powder spraying areas
must be avoided. There must be sufficient technical ventilation
available, to prevent a dust concentration of more than 50% of
the lower explosion limit (UEG) (UEG = max. permissible powder/air concentration). If the UEG is not known then a value of 10
g/m³ should be used.
A summary of the rules and regulations
The following is a list of relevant rules and regulations which are to be
observed:
8  General safety regulations
OptiFlex S manual coating equipment
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Guidelines and regulations, German professional association
BGV A1
General regulations
BGV A2
Electrical equipment and material
BGI 764
Electrostatic coating
BGR 132
Guidelines for the avoidance of the dangers of ignition
due to electrostatic charging (Guideline “Static Electricity”)
VDMA 24371
Guidelines for electrostatic coating with synthetic powder1)
- Part 1 General requirements
- Part 2 Examples of use
Leaflets
ZH 1/310
Leaflet for the use of tools in locations where there is
danger of explosion 1)
EN European standards
RL94/9/EC
The approximation of the laws of the Member States
relating to apparatus and safety systems for their intended use in potentially explosive atmospheres
EN 292-1
EN 292-2
Machine safety 2)
EN 50 014 to EN
50 020, identical:
DIN VDE
0170/0171
Electrical equipment for locations where there is danger
of explosion 3)
EN 50 050
Electrical apparatus for potentially explosive atmospheres - Electrostatic hand-held spraying equipment 2)
EN 50 053, part 2
Requirements for the selection, installation and use of
electrostatic spraying equipment for flammable materials - Hand-held electrostatic powder spray guns 2)
EN 50 177
Stationary electrostatic spraying equipment for flammable coating powder 2)
PR EN 12981
Coating plants - Spray booths for application of organic
powder coating material - Safety requirements
EN 60 529, identical: DIN 40050
IP-Type protection: contact, foreign bodies and water
protection for electrical equipment 2)
EN 60 204 identical: DIN VDE 0113
VDE regulations for the setting up of high-voltage electrical machine tools and processing machines with
mains voltages up to 1000 V 3)
VDE (Association of German Engineers) Regulations
DIN VDE 0100
Regulations for setting-up high voltage equipment with
mains voltages up to 1000V 4)
DIN VDE 0105
VDE regulations for the operation of high voltage
equipment 4)
part 1
General regulations
part 4
Supplementary definitions for stationary electrical spraying equipment
DIN VDE 0147
part 1
Setting up stationary electrostatic spraying equipment 4)
DIN VDE 0165
Setting up electrical equipment in locations in areas with
danger of explosion 4)
OptiFlex S manual coating equipment
General safety regulations  9
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*Sources:
1)
Carl Heymanns Verlag KG, Luxemburger Strasse 449, 5000 Köln 41,
or from the appropriate employers association
2)
Beuth Verlag GmbH, Burgrafenstrasse 4, 1000 Berlin 30
3)
General secretariat, Rue Bréderode 2, B-1000 Bruxelles, or the appropriate national committee
4)
VDE Verlag GmbH, Bismarckstrasse 33, 1000 Berlin 12
Product specific security measures
10  General safety regulations
-
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, that all components are grounded according to the local regulations, before start-up
OptiFlex S manual coating equipment
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About this manual
General information
This operating manual contains all important information which you require for the working with the OptiFlex S 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.
OptiFlex S manual coating equipment
About this manual  11
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Function description
Field of application
The OptiFlex S manual coating equipment (with stirrer recipient) is built
exclusively for electrostatic coating with organic powders. Any other use
of the product will be considered as non intended use. The manufacturer
is not responsible for any damage resulting from this; the risk is assumed
by the user alone!
The OptiFlex S electrostatic powder manual coating equipment with the
OptiSelect manual powder gun is ideally suited for manual coating of objects in larger series.
Typical characteristics
OptiFlex S manual coating equipment
-
Processing the powder from the stirrer recipient
-
Quick and simple color change
-
Supplied ready for use
-
Available with one or two guns (extensible)
Function description  13
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OptiFlex S manual coating equipment
Structure
11
2
1
5
12
3
8
10
9
7
13
4
6
OptiFlex S manual coating equipment - structure
1
OptiStar control unit
8
9
Hose holder
2
OptiSelect manual powder gun
3
OptiFlow injector
10
Discharge flap
Hose connections
4
Mobile frame with hand rail
11
Filler flap
5
Stirrer recipient
12
Shelf
6
Swivel wheel
13
Rubber wheel
7
Filter unit
OptiStar control unit
All information about the OptiStar control unit will be found in the corresponding enclosed documentation!
OptiFlow injector
All information about the OptiFlow injector will be found in the corresponding enclosed documentation!
14  Function description
OptiFlex S manual coating equipment
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Stirrer recipient
The powder in the stirrer recipient is agitated and kept loose by the stirrer
arm. The injector sucks in the powder by means of the conveying air (1).
The powder/air mixture attains to the gun through the powder hose (2)
and is electrostatically charged in the gun nozzle. In addition, an electrostatic field is created between the gun nozzle and the grounded object.
The electrostatically charged powder sprayed onto the workpiece adheres on the surface of the grounded object. Because of the conical
shape of the stirrer recipient, the powder can be used completely (optimum powder consumption).
Conveying air, supplementary air and rinsing air are set on the OptiStar
control unit (see therefore the corresponding user manual). The function
of the used injector is described in the corresponding user manual.
2
1
Stirrer recipient - function
OptiFlex S manual coating equipment
Function description  15
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Scope of delivery
OptiFlex 1-S
-
A OptiStar control unit in a metal case with power supply
cable
-
A mobile trolley with a gun/hose support
-
A powder recipient with stirrer and cover, inclusive mains
adaptor for the stirrer
-
A plug-in OptiFlow injector
-
An OptiSelect manual powder gun with gun cable,
powder hose, rinsing air hose and standard nozzle set
(see therefore the OptiSelect manual powder gun user
manual)
-
Pneumatic hoses for conveying air (red) and supplementary air (black)
Additional supply for OptiFlex 2-S
16  Function description
-
An additional OptiStar control unit, complete with gun
holder, special powder supply cable and connecting material
-
An additional OptiSelect manual powder gun with gun cable, powder hose, rinsing air hose and standard nozzle set
-
Pneumatic hoses for conveying air (red), supplementary
air (black), as well as a pneumatic connection with dual
distributor from pressure reducing valve to control unit
-
Mains adaptor for twin equipment
OptiFlex S manual coating equipment
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Technical Data
OptiFlex S manual coating equipment
Electrical Data
OptiFlex S manual coating equipment
Nominal input voltage
230-240 VAC
(110-120 VAC)
Frequency
50/60 Hz
Input value
150 VA
Nominal output voltage (to the gun)
max. 12 V
Nominal output current (to the gun)
max. 1 A
Protection type
Temperature range
IP54
0-40°C
(+32°F - +104°F)
Approvals
Pneumatical Data
OptiFlex S manual coating equipment
Compressed air main connection
Max. input pressure
Min. input pressure
Max. water vapor content of compressed air
Max. oil vapor content of compressed air
Max. compressed air consumption
G1/4" internal thread
10 bar
6 bar
1,3 g/m³
0,1 mg/m³
7 m³/h
Connectable guns
OptiFlex S manual coating equipment
OptiSelect GM02
OptiGun GA02
PG1/PG2-A
TriboJet
connectable
yes
yes
yes (no remote control)
yes, with adapter*
* The gun type must be set on the control unit (see therefore the corresponding user manual)!
OptiFlex S manual coating equipment
Technical Data  17
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Attention:
The OptiFlex S manual coating equipment may be used only with
the specified gun types!
Dimensions
OptiFlex S manual coating equipment
18  Technical Data
Width
691 mm
Depth
764 mm
Height
1135 mm
Weight
58 kg
OptiFlex S manual coating equipment
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Start-up and operation
Connecting guide
1. Check the compressed air connection from the filter unit to
the control unit. Connect the compressed air supply hose
from the compressed air circuit directly to the filter unit main
connection on the rear side of the equipment (1/4" female
BSP)
Note:
The compressed air must be free from oil and water!
2. Connect the grounding cable to the control unit with the
grounding screw, and the 5 m long grounding cable with the
clamping clip to the booth or the conveyor. Check ground
connections with Ohm meter and ensure 1 MOhm or less
3. Connect the gun cable plug to the socket 2.3 on the rear side
of the control unit
4. Connect the rinsing air hose to the electrode rinsing air output 1.4 and to the powder gun
5. Attach the injector, connect the powder hose to the injector
and to the powder gun
6. Connect the red hose for conveying air to the corresponding
output 1.2 on the rear side of the control unit and to the injector
7. Connect the black hose for supplementary air to the corresponding output 1.3 on the rear side of the control unit and to
the injector (this hose is electrically conducting)
8. Connect the mains cable to the 2.1 Power IN plug and tighten with provided screw
Note:
If no stirrer is connected, the 2.2 Aux output is to be locked tightly
with the provided protection cap!
OptiFlex S manual coating equipment
Start-up and operation  19
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Gun
Air supply IN
Filter unit
Power IN
Aux
Gun
2.1
2.2
2.3
6 - 10 bar
87 - 145 PSI
1.5
1.4
1.3
1.2
Fluidizing air
Injector
Connecting guide - overview
Preparation for start-up
Fill the stirrer recipient with powder
1. Open the hinged flap of the stirrer recipient cover
2. Fill in the coating powder in the stirrer recipient. Maximum filling
level of the powder is marked on the inside of the recipient (useful capacity approx. 18.5 dm³)
3. Close the hinged flap of the stirrer recipient cover
4. The stirrer can be put into operation by pressing manually the
button on the cover when filling/emptying
Switching on the booth
The coating booth is switched on according to the corresponding user
manual.
Start-up
Stirrer
The stirrer starts by pressing the gun trigger. By letting loose the gun
trigger, the stirrer runs after for approx. 15-20 seconds. So open the cover only after the stirrer has stopped! By raising the stirrer cover, the engine switches off.
20  Start-up and operation
OptiFlex S manual coating equipment
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Switch on the control unit
1. Press the ON power switch.
The displays illuminate and the control unit is ready for operation
Note:
The further start-up procedure for the OptiFlex S manual coating
equipment gun is explicitly described in the OptiStar CG07control
unit operating instructions (chapter "Initial start-up" and "Daily
start-up")!
OptiFlex S manual coating equipment
Start-up and operation  21
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Color change
General information
When a color change takes place, the individual components of the manual coating equipment must be cleaned carefully. Thereby, all powder
particles of the former color must be removed!
Procedure:
1. Empty the stirrer recipient and clean thoroughly
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 manual of the OptiSelect manual powder gun)
4. Clean the injector (see therefore the user manual of the OptiFlow
injector)
5. Prepare the manual coating equipment with new powder for
start-up
OptiFlex S manual coating equipment
Color change  23
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Maintenance and cleaning
Note:
Regular and conscientious maintenance increases the life span of
the manual coating equipment and provides for a longer continuous
coating quality!
Daily maintenance
1. Clean the injector (see therefore the user manual of the OptiFlow
injector)
2. Clean the powder gun (see therefore the user manual of the OptiSelect manual powder gun)
3. Clean the powder hose, see therefore in chapter "Color change"
Weekly maintenance
1. Clean the stirrer recipient, the injector and the powder gun
2. Check the control unit grounding connections to the coating
booth, the suspension devices of the work pieces, or the conveyor 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 hose rinsing
If lengthy downtimes take place, the powder hose must be cleaned.
Procedure:
1. Strip the powder hose from the hose connection on the injector
2. Point the gun into the booth
3. Blow through the hose manually with a compressed air gun
4. Fit the powder hose again to the hose connection on the injector
OptiFlex S manual coating equipment
Maintenance and cleaning  25
V 05/10
Cleaning
Cleaning the OptiSelect manual powder gun
Frequent cleaning of the gun helps to 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 out the gun from the connection in flow direction with compressed air
5. Clean the integrated gun tube with the provided gun brush
6. Blow through the gun with compressed air again
7. Clean the powder hose
8. Reassemble the gun and connect it
Note:
See therefore the user manual of the OptiSelect manual powder
gun!
Maintenance and cleaning of the filter unit
The filter unit on the OptiFlex F manual 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
26  Maintenance and cleaning
OptiFlex S manual coating equipment
V 05/10
Fault elimination
General information
Fault
Causes
Fault elimination
---
Power pack defective
Replace the power pack
---
Main valve defective
Replace main valve coil
---
Gun not connected
Connect the gun
Gun plug, gun cable or
gun cable connection
defective
Replace corresponding
part or send in for repair
Remote control on
powder gun defective
Replace remote control
(gun cap)
---
Rinsing air solenoid
valve of flat jet nozzle
defective
Replace valve 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
Replace corresponding
part or send in for repair
Remote control on
powder gun defective
Powder does not adhere to object, although the gun trigger
is operated and the
gun sprays powder
OptiFlex S manual coating equipment
Replace remote control
(gun cap)
High-voltage and current deactivated
Press the selection key
(application key)
High voltage cascade
defective
Send in the gun for repair
Objects are not properly
grounded
Check the grounding
Fault elimination  27
V 05/10
Fault
Causes
Fault elimination
Control unit displays
remain dark, although
the control unit is
switched on
Control unit is not connected to the mains
Connect the equipment
with the mains cable
Power pack fuse defective
Replace the fuse
Power pack defective
Replace the power pack
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
Motor throttle defective
Replace the motor throttle
Compressed air not
present
Connect the equipment
to the compressed air
Injector, motor throttle or
nozzle on injector,
powder hose or powder
gun are clogged
Clean corresponding
part
Nozzle in the injector is
clogged
Replace
Nozzle is not inserted
Insert the insert sleeve
Fluidizing not running
(see above)
The powder is not fluidized
The gun does not
spray powder, although the control unit
is switched on and the
gun trigger is operated
No conveying air:
28  Fault elimination
Motor throttle defective
Replace the motor throttle
Solenoid valve defective
Replace the solenoid
valve
Front plate defective
Send in for repair
OptiFlex S manual coating equipment
V 05/10
Schematic diagrams
Block diagram - OptiFlex S
Block diagram - OptiFlex S
OptiFlex S manual coating equipment
Schematic diagrams  29
V 05/10
Pneumatic diagram - OptiFlex S
Supplementary air
Zusatzluft
OptiStar CG07
Conveying
Förderluft air
E1
24V
M1
1.1
1.5
M1
1.4
M1
1.3
M1
1.2
Adjust to 5,5 bar by
Auf 5.5 bar
6 Nm³/h
einstellen beiair conLuftverbrauch
sumption
6 Nm3/h
Elektrodenspülluft
Elektrodenspüluft
Electrode
rinsing air
3-10
l/min
3-10
3-10 l/min
l/min.
M1 = Motor throttle
M1 = Motordrossel
E1 = InputE1unit
= Eingangseinheit
Pneumatic diagram - OptiFlex S
30  Schematic diagrams
OptiFlex S manual coating equipment
V 05/10
Spare parts list
Ordering spare parts
When ordering spare parts for powder coating equipment, please indicate
the following specifications:
-
Type and serial number of your powder coating equipment
-
Order number, quantity and description of each spare part
Example:
-
Type OptiFlex S manual coating equipment
Serial number 1234 5678
-
Order no. 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 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 be used, because the
explosion protection will also be preserved that way. The use of
spare parts from other manufacturers will invalidate the ITW Gema
guarantee conditions!
OptiFlex S manual coating equipment
Spare parts list  31
V 05/10
OptiFlex S manual coating equipment - spare parts list
1
Bearing bolt
1000 453
2
Hexagon shakeproof nut - M6
3
Countersunk Allen screw - M6x30 mm
1002 952
4
Handle bar
1002 623
5
Counter washer
1000 944
6
Rubber wheel - Ø 200 mm
260 592
7
Swivel wheel - Ø 50 mm
260 606
8
Grounding cable - complete
301 140
9
Countersunk Allen screw - M6x20 mm
1002 992
10
Clamp
1003 077
11
Countersunk Allen screw - M6x40 mm
1002 953
12
Gun retainer
1003 076
13
CG07 gun control unit - complete (not shown, see corresponding user manual)
14
Plastic hose - Ø 8/6 mm, black
103 756*
15
Hose holder
1000 699
16
Filter unit - complete (see corresponding spare parts list)
17
Stirrer recipient (see corresponding spare parts list)
18
Ribbed cylinder Allen screw - M10x20 mm
260 584
19
Snap ring - A-25
237 094
20
Hexagon ribbed cylinder screw - M8x16 mm
261 793
21
OptiFlow IG02-V injector - complete (see corresponding user manual)
22
Spare parts set - MS03, consisting of:
244 430
1002 016
Insert sleeve PTFE
377 724
Injector plug gauge
393 380
O-ring - Ø 16x2 mm
231 517
Fuse - 4 AT
262 897
Fuse - 2 AT
221 872
Fuse - 0.1 AT
229 520
Cable tie - L=100x2.5 mm
200 719
23
Short instruction sheet OptiStar CG07
1002 060
24
Program table sheet OptiStar CG07
1002 063
* Please indicate length
32  Spare parts list
OptiFlex S manual coating equipment
V 05/10
OptiFlex S manual coating equipment - spare parts
4
23
22
9
12
10
24
17
11
15
8
16
3
14
21
1
5
20
6
19
7
18
OptiFlex S manual coating equipment - spare parts
OptiFlex S manual coating equipment
Spare parts list  33
V 05/10
OptiFlex S - stirrer recipient
1
Mini stirrer brush
366 862
2
Main filler cover
1001 730
3
Filler flap
1001 731
4
Hinge
305 472
5
Powder container
366 854
6
Gasket for powder container
101 630*
7
Cardan joint - Ø 12 mm, H7
206 369
8
Protective cover for cardan joint
206 350
9
Manifold
379 395
10
O-ring - Ø 67.2 mm
236 403
11
Gasket for discharge flap
303 240
12
Discharge flap with toggle clamp, incl. pos. 11
303 194
13
Blind grommet - complete, incl. pos. 14
380 296
14
O-ring for blind grommet
15
Injector retainer
380 288
16
Wedge for cardan joint - 4x4x12 mm, round
269 263
17
Grub screw for cardan joint - M4x4x16 mm, round
206 075
18
Grub screw for cardan joint - hexagon, spiky
214 728
19
Countersunk Allen screw - M3x10 mm
248 444
20
Shakeproof Allen screw - M6x16 mm
261 823
21
Shakeproof Allen screw - M5x12 mm
257 052
22
Injector OptiFlow IG02-V - complete (see corresponding user manual)
231 517#
# Wearing part
* Please indicate length
34  Spare parts list
OptiFlex S manual coating equipment
V 05/10
OptiFlex S - stirrer recipient
2
4
3
6
5
16
1
8
7
21
18
10
17
9
13
22
14
19
20
11
12
OptiFlex S - stirrer recipient
OptiFlex S manual coating equipment
Spare parts list  35
V 05/10
OptiFlex S - stirrer drive unit
Stirrer drive unit - complete (pos. 1-13)
393 940
1
Stirrer motor (with gear unit and stirrer case)
393 932
2
Stirrer motor (with pinion)
268 950
Stirrer motor
269 255
Drive belt
268 941
3
Electronic board for stirrer control - complete, incl pos. 5
388 173
4
Stirrer control power supply
389 277
5
Mains push button - complete, with cable
390 542
Cable set, consisting of:
6
Power pack connecting cable
390 550
7
Connecting cable 24 VDC
390 569
8
Grounding wire
391 867
9
Fixture set for power pack board, consisting of two pieces each:
Standoff - M3, SW5,5x12 mm
267 775
Standoff - M3, SW5,5x10 mm
267 007
Cylinder screw
245 321
Shake proof washer
205 885
10
Fuse - 2 AT
221 872
11
Adaptor cable for stirrer connection
391 905
12
Gland
265 780
13
Gasket for stirrer motor
393 924
36  Spare parts list
OptiFlex S manual coating equipment
V 05/10
OptiFlex S - stirrer drive unit
11
13
12
2
1
4
3
10
9
4
5
7
3
10
6
8
OptiFlex S - stirrer drive unit
OptiFlex S manual coating equipment
Spare parts list  37
V 05/10
OptiFlex S - filter unit
Filter unit - complete, without pos. 14
1001 147
1
Filter separator - MAF200L-8A
1007 321
2
T-piece - 1/4"i-1/4"a-1/4"i
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
262 064
9
1
2
12
3
10
11
14
11
7
OptiFlex S - filter unit
38  Spare parts list
OptiFlex S manual coating equipment
V 05/10
OptiFlex S manual coating equipment
Spare parts list  39
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