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

Documentation OptiFlex S manual coating equipment

© Copyright 2006 ITW Gema GmbH

All rights reserved.

This publication is protected by copyright. Unauthorized copying is prohibited by law. No part of this publication may be reproduced, photocopied, 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

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

Table of contents

 1

OptiFlex S manual coating equipment

Color change 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


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


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

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 Protection type Temperature class

0102 II (2) D

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


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.


 5

6


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


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 ITW-

Gema 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.


 7

8


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:


Guidelines and regulations, German professional association

BGV A1 General regulations

BGV A2 Electrical equipment and material

BGI 764

BGR 132

VDMA 24371

Electrostatic coating

Guidelines for the avoidance of the dangers of ignition due to electrostatic charging (Guideline “Static Electricity”)

Guidelines for electrostatic coating with synthetic powder

1)

- 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

EN 292-1

EN 292-2

The approximation of the laws of the Member States relating to apparatus and safety systems for their intended use in potentially explosive atmospheres

Machine safety

2)

EN 50 014 to EN

50 020, identical:

DIN VDE

0170/0171

EN 50 050

Electrical equipment for locations where there is danger of explosion

3)

EN 50 053, part 2

EN 50 177

PR EN 12981

EN 60 529, identical: DIN 40050

Electrical apparatus for potentially explosive atmospheres - Electrostatic hand-held spraying equipment

2)

Requirements for the selection, installation and use of electrostatic spraying equipment for flammable materials - Hand-held electrostatic powder spray guns

2)

Stationary electrostatic spraying equipment for flammable coating powder

2)

Coating plants - Spray booths for application of organic powder coating material - Safety requirements

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 part 1 part 4

VDE regulations for the operation of high voltage equipment

4)

General regulations

Supplementary definitions for stationary electrical spraying equipment

Setting up stationary electrostatic spraying equipment

4)

DIN VDE 0147 part 1

DIN VDE 0165 Setting up electrical equipment in locations in areas with danger of explosion

4)


 9

*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

-

-

-

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

10



About this manual


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

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

-

-

-

-

Processing the powder from the stirrer recipient

Quick and simple color change

Supplied ready for use

Available with one or two guns (extensible)

OptiFlex S manual coating equipment Function description

 13


Structure

11

5

3

10

4

6

OptiFlex S manual coating equipment - structure

1 OptiStar control unit

2 OptiSelect manual powder gun

8 Hose holder

9 Hose connections

4 Mobile frame with hand rail 11 Filler flap

12 Shelf

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!

8

9

7

2

1

12

13

14

 Function description


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.

Stirrer recipient - function

2

1

OptiFlex S manual coating equipment Function description

 15

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

-

-

-

-

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

16

 Function description


Technical Data


Electrical Data


Nominal input voltage

230-240 VAC

(110-120 VAC)

Input value

Nominal output voltage (to the gun)

Nominal output current (to the gun)

150 VA max. 12 V max. 1 A

Protection type

Temperature range

IP54

0-40°C

(+32°F - +104°F)

Approvals

Pneumatical Data


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


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

Attention:

The OptiFlex S manual coating equipment may be used only with the specified gun types!

Dimensions


18

 Technical Data


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!

Start-up and operation

 19


Gun

Filter unit

Air supply IN 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


Switch on the control unit

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

Color change


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

Color change

 23


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

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


Fault elimination


Fault

---

---

---

---

---

---

Gun LED remains dark, although the gun trigger is operated

Powder does not adhere to object, although the gun trigger is operated and the gun sprays powder

Causes

Power pack defective

Main valve defective

Gun not connected

Gun plug, gun cable or gun cable connection defective

Remote control on powder gun defective

Rinsing air solenoid valve of flat jet nozzle defective

Rinsing air solenoid valve of round jet nozzle defective



Remote control on powder gun defective

High-voltage and current deactivated

High voltage cascade defective

Objects are not properly grounded


Replace the power pack

Replace main valve coil

Connect the gun

Replace corresponding part or send in for repair

Replace remote control

(gun cap)

Replace valve coil

Replace valve coil



Replace remote control

(gun cap)

Press the selection key

(application key)

Send in the gun for repair

Check the grounding


 27


Fault

Control unit displays remain dark, although the control unit is switched on

The powder is not fluidized

The gun does not spray powder, although the control unit is switched on and the gun trigger is operated

Causes

Control unit is not connected to the mains

Power pack fuse defective

Power pack defective

Compressed air not present

Fluidizing air is set too low on the control unit

Motor throttle defective

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 running

No conveying air:

Motor throttle defective

Solenoid valve defective

Front plate defective


Connect the equipment with the mains cable

Replace the fuse

Replace the power pack

Connect the equipment to the compressed air

Set the fluidizing air correctly

Replace the motor throttle

Connect the equipment to the compressed air

Clean corresponding part

Replace

Insert the insert sleeve

(see above)

Replace the motor throttle

Replace the solenoid valve

Send in for repair

28

 Fault elimination


Schematic diagrams

Block diagram - OptiFlex S

Block diagram - OptiFlex S

OptiFlex S manual coating equipment Schematic diagrams

 29

Pneumatic diagram - OptiFlex S

OptiStar CG07

E1

24V

M1 M1 M1 M1

Adjust to 5,5 bar by

6 Nm³/h air con-

Luftverbrauch

1.1 1.5 1.4 1.3 1.2

Supplementary air

Zusatzluft

Electrode rinsing air

3-10 l/min

Pneumatic diagram - OptiFlex S

M1 = Motor throttle

M1 = Motordrossel

30

 Schematic diagrams


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

-

Example:

Order number, quantity and description of each spare part

-

-

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!


 31


OptiFlex S manual coating equipment - spare parts list

1

Bearing bolt

2 Hexagon shakeproof nut - M6

3 Countersunk Allen screw - M6x30 mm

4

Handle bar

5 Counter washer

6 Rubber wheel - Ø 200 mm

7 Swivel wheel - Ø 50 mm

8 Grounding cable - complete


10 Clamp


12 Gun retainer

13 CG07 gun control unit - complete (not shown, see corresponding user manual)

14 Plastic hose - Ø 8/6 mm, black

15 Hose holder

16 Filter unit - complete (see corresponding spare parts list)

17 Stirrer recipient (see corresponding spare parts list)

18 Ribbed cylinder Allen screw - M10x20 mm

19 Snap ring - A-25

20 Hexagon ribbed cylinder screw - M8x16 mm

21 OptiFlow IG02-V injector - complete (see corresponding user manual)

22 Spare parts set - MS03, consisting of:

Insert sleeve PTFE

Injector plug gauge

O-ring - Ø 16x2 mm

Fuse - 4 AT

Fuse - 2 AT

Fuse - 0.1 AT

Cable tie - L=100x2.5 mm

23 Short instruction sheet OptiStar CG07

24 Program table sheet OptiStar CG07

* Please indicate length

1000 453

244 430

1002 952

1002 623

1000 944

260 592

260 606

301 140

1002 992

1003 077

1002 953

1003 076

103 756*

1000 699

260 584

237 094

261 793

1002 016

377 724

393 380

231 517

262 897

221 872

229 520

200 719

1002 060

1002 063

32

 Spare parts list


OptiFlex S manual coating equipment - spare parts

4 22 23

9

12

10

11

15

16

3

17

8

24

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

OptiFlex S - stirrer recipient

1 Mini stirrer brush

2 Main filler cover

3 Filler flap

4 Hinge

5

Powder container

6 Gasket for powder container

7 Cardan joint - Ø 12 mm, H7

8 Protective cover for cardan joint

9 Manifold

10 O-ring - Ø 67.2 mm

11 Gasket for discharge flap

12 Discharge flap with toggle clamp, incl. pos. 11

13 Blind grommet - complete, incl. pos. 14

14

O-ring for blind grommet

15 Injector retainer

16 Wedge for cardan joint - 4x4x12 mm, round

17 Grub screw for cardan joint - M4x4x16 mm, round

18 Grub screw for cardan joint - hexagon, spiky


20 Shakeproof Allen screw - M6x16 mm

21 Shakeproof Allen screw - M5x12 mm

22 Injector OptiFlow IG02-V - complete (see corresponding user manual)

# Wearing part

* Please indicate length

303 240

303 194

380 296

231 517#

380 288

269 263

206 075

214 728

248 444

261 823

257 052

366 862

1001 730

1001 731

305 472

366 854

101 630*

206 369

206 350

379 395

236 403

34



OptiFlex S - stirrer recipient

2

6

4

3

5

1

21

13

14

20

OptiFlex S - stirrer recipient

10

9

11

12

22

19

7


 35

16

8

18

17

OptiFlex S - stirrer drive unit

Stirrer drive unit - complete (pos. 1-13)

1 Stirrer motor (with gear unit and stirrer case)

2 Stirrer motor (with pinion)

Drive belt

3 Electronic board for stirrer control - complete, incl pos. 5

4

Stirrer control power supply

5 Mains push button - complete, with cable

Cable set, consisting of:

6 Power pack connecting cable

7 Connecting cable 24 VDC

8

Grounding wire

9 Fixture set for power pack board, consisting of two pieces each:

Standoff - M3, SW5,5x12 mm

Standoff - M3, SW5,5x10 mm

Cylinder screw

Shake proof washer

10 Fuse - 2 AT

11 Adaptor cable for stirrer connection

12

Gland

13 Gasket for stirrer motor

390 550

390 569

391 867

267 775

267 007

245 321

205 885

221 872

391 905

265 780

393 924

393 940

393 932

268 950

269 255

268 941

388 173

389 277

390 542

36



OptiFlex S - stirrer drive unit

11

13

12

4

10

4

7

10

6

OptiFlex S - stirrer drive unit


9

2

1

3

5

3

8


 37

OptiFlex S - filter unit

Filter unit - complete, without pos. 14

1 Filter separator - MAF200L-8A

2 T-piece - 1/4"i-1/4"a-1/4"i

3 Elbow joint - 1/4"-3xØ 8-8 mm

7 Filter cartridge - 20 µm

9 Manometer - G1/4", 0-10 bar

10 Rectus nipple - NW 7.4-1/4"a

11 Grommet - Ø 8 mm

12 Elbow joint - 1/4"i-1/4"a

14 Rectus quick release connection (for pos. 10) - NW 7.8-Ø 10 mm

9

1

2

3

11

11

OptiFlex S - filter unit

7

12

10

14

1001 147

1007 321

262 064

1007 327

1007 325

1007 328

256 730

238 023

222 674

239 267

38




 39

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