Powder injector OptiFlow (type IG06)

Powder injector OptiFlow (type IG06)
En
Operating instructions and spare parts list
Powder injector
OptiFlow (type IG06)
Translation of the original operating instructions
V 08/13
Documentation OptiFlow (type IG06)
© Copyright 2008 Gema Switzerland 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 Gema Switzerland
GmbH.
OptiStar, OptiTronic, OptiGun, OptiSelect, EasyTronic, EasySelect,
EasyFlow and SuperCorona are registered trademarks of Gema
Switzerland GmbH.
OptiFlex, OptiMatic, OptiMove, OptiMaster, OptiPlus, MultiTronic and
Gematic are trademarks of Gema Switzerland 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. Gema Switzerland
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
Gema Switzerland 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.gemapowdercoating.com
V 08/13
Table of contents
OptiFlow - plug-in injector for organic powder
3
Field of application .................................................................................................. 3
Principle of the injector and influence of supplementary air ................................... 4
Powder volume setting table for OptiFlow Injector ................................................. 5
General conditions for the OptiFlow Injector.............................................. 5
Guide values for OptiStar with OptiFlow Injector ....................................... 5
Cleaning and maintenance
7
Cleaning the injector ............................................................................................... 7
Cleaning the check valve units ............................................................................... 8
Troubleshooting guide
9
Problem fixing ......................................................................................................... 9
Spare parts list
11
Ordering spare parts ............................................................................................. 11
OptiFlow Powder injector (type IG06) ................................................................... 12
OptiFlow (type IG06)
Table of contents • 1
V 08/13
OptiFlow - plug-in injector for organic
powder
Field of application
The OptiFlow injector is used for conveying normal organic powders
between the powder hopper and the powder gun. The injector is supplied
with a PTFE insert sleeve as standard.
The OptiFlow Injector is a plug-in type and permits easy handling and
quick cleaning. All connections are plug-in types and not
interchangeable. The injector can be disassembled without special tools.
OptiFlow Powder injector (IG06 type) with coded quick release connections
Note:
The injector is certified for using in the following zone, if powder
hoses with conductive strips are used, and the earthing resistance
is less than 1 MOhm!
Explosion protection
II 3 D
OptiFlow (type IG06)
Zone
22
OptiFlow - plug-in injector for organic powder • 3
V 08/13
Principle of the injector and influence of
supplementary air
When air flows through a nozzle into a cavity with an attached outlet in
the continuation of the airflow, a vacuum will be created in the cavity (see
figure below). This effect is used now for aspirating powder through a
suction opening - a powder/air mixture will be created.
Conveying air
Supplementary air
Insert sleeve
to the gun
Nozzle
Powder/air mixture
Powder hopper
Vacuum
Suction tube
fluidized powder
This powder/air mixture is fed through to the powder hose to the gun. The
concentration of the powder/air mixture and therefore the powder output
amount, depends on the conveying and supplementary air volume, the
powder quality, the powder hose length, the powder hose diameter, the
number of coils in the hose, the height difference between the powder
gun and the injector and the nozzle type. Place great importance on the
insert sleeve condition, because wear causes the powder output to
reduce drastically.
Experience with pneumatic material handling technology shows that
pneumatic transport of fine solid matter (powder) in the form of tubing
(hose), the transporting medium requires a certain volume of air per unit
of time. If a hose diameter of 11 mm is used, the value is approx. 4 m³/h.
In order to reduce the powder output, the vacuum in the cavity of the
injector must be lowered by reducing the conveying air pressure. By
reducing the conveying air pressure, the air volume in the powder hose
sinks to below the optimum value of 4 m³/h, the powder transport
becomes irregular and the so-called "pumping" takes place. To prevent
this from happening, the supplementary air is added, until the total air
volume in the powder hose amounts again to 4-5 m³/h. This takes place
fully automatically by the OptiStar Control unit.
4 • OptiFlow - plug-in injector for organic powder
OptiFlow (type IG06)
V 08/13
Powder volume setting table for OptiFlow Injector
OptiStar
In order to set the ideal powder volume on the OptiStar, it is
recommended to select first the powder cloud firmness, respectively the
total air. As guide values for different powder hoses, the following can be
assumed:
•
Powder hose 74 type, Ø 10 mm, 3-5 m³/h
•
Powder hose 66 type, Ø 11 mm, 4-5 m³/h
According to the prevailing conditions (powder, powder hose layout, the
parts to be coated) a low to lowest total air can also be set with the
standard hose 74 type, Ø 10 mm.
If a very large powder output is required, it is recommended to select a
larger powder hose internal diameter (Ø 12 mm).
Note:
It should to be noted, that if irregular or pumping conveying occurs,
as a rule, the total air is set too low!
General conditions for the OptiFlow Injector
Powder type
Epoxy/polyester
Powder hose length (m)
12
Powder hose Ø (mm)
11
Input pressure (bar)
5,0
Conveying air nozzle (mm)
1,6
Supplementary air nozzle Ø (mm)
1,4
Guide values for OptiStar with OptiFlow Injector
All values in these tables are guide values. Differing environmental
conditions, wear and different powder types can affect the table values.
3 Nm³/h
Total air
OptiStar
5 Nm³/h
Powder output (g/min)
Powder output
OptiFlow (type IG06)
4 Nm³/h
(%)
20
40
60
80
100
60
115
175
220
250
70
140
210
260
300
80
160
220
270
310
OptiFlow - plug-in injector for organic powder • 5
V 08/13
Cleaning and maintenance
Cleaning the injector
1. Remove the injector
2. Remove the powder hose from hose connection (4)
3. Clean the hose connection (4) with compressed air which is
free of oil and water, and check for wear
4. Clean the injector body (1) with compressed air which is free
of oil and water Possible contaminations are visible through
the opening of the powder hopper connection (2)
5. Reinsert the injector and fix it
WARNING!
If the injector is severely contaminated, it must be dismantled.
Remove the check valve units (6 and 7) with the correct sized
spanner. Clean the component parts with compressed air and, if
necessary, dissolve sintered deposits with nitro-thinner. Do not use
acetone, do not scrape!
7
6
4
1
2
OptiFlow (type IG06)
1
Injector housing
2
Powder hopper connection 7
6
4
Powder hose connection
Check valve unit (conveying air)
Check valve unit (supplementary air)
Cleaning and maintenance • 7
V 08/13
Cleaning the check valve units
Note:
Take care when dismantling the check valve units!
Blow off the filter elements from the inside to the outside!
1
2
3
1
Connection/plug
2
O-ring
3
Filter element
Note:
Do not immerse the filter elements in fluidities or solvents!!!
8 • Cleaning and maintenance
OptiFlow (type IG06)
V 08/13
Troubleshooting guide
Problem fixing
If the powder gun does not spray powder although the control unit is
switched on, then the injector can be dirty or clogged.
OptiFlow (type IG06)
Error/cause
Troubleshooting
Injector nozzle, check valve unit,
powder hose or powder gun are
clogged
Clean the corresponding parts
and if necessary, replace them
Conveying vacuum too low
Increase the powder quantity
and/or total air volume on the
control unit
Insert sleeve worn, not or incorrect
inserted
Replace or insert it, observe the
indexing cam
Insert sleeve is worn after a short
operating duration
Clean the nozzle, if damaged,
replace it
Troubleshooting guide • 9
V 08/13
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
-
Type OptiFlow (type IG06)
Serial number 1234 5678
-
Order no. 203 386, 1 piece, Clamp - Ø 18/15 mm
Example:
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 wearing parts are always marked with a #.
All dimensions of plastic hoses are specified with the external and
internal diameter:
Example:
Ø 8/6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d)
WARNING!
Only original 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 Gema
guarantee conditions!
OptiFlow (type IG06)
Spare parts list • 11
V 09/13
OptiFlow Powder injector (type IG06)
OptiFlow IG06 Powder injector - complete (pos. 1-13)
1007 780
A
Conveying air check valve unit (red marking) - complete (incl. pos. 6, 8, 9 and 12)
1005 589
B
Supplementary air check valve unit (black marking) - complete (incl. pos. 7, 8, 9 and
13)
1005 590
C
Injector body - complete (incl. pos. 1, 2, 10 and 11)
1006 530
1
Injector body (without pos. 2)
1006 484
2
O-ring - Ø 16x2 mm
1007 794#
3
Insert sleeve - PTFE, complete
1006 485#
4
Hose connection - Ø 10-12 mm, complete (incl. pos 4.1)
1006 531
O-ring - Ø 16x1.5 mm
205 141#
5
Threaded sleeve
1006 483
6
Connector (conveying air) - NW 5.5
1004 366
7
Connector (supplementary air) - NW 5.5
1004 367
8
O-ring - Ø 11x1.5 mm
9
Filter element - Ø 9/4x27 mm
1003 698#
10
Nozzle
1006 488
11
Nozzle fixation - complete (incl. pos. 11.1)
1007 792
4.1
11.1
O-ring - Ø 8x1 mm
1000 532#
1007 793#
12
Body (red)
1004 369
13
Body (black)
1004 370
16
Conveying air hose - Ø 8/6 mm (red)
103 500*
17
Supplementary air hose - Ø 8/6 mm (black)
103 756*
18
Quick release coupling for conveying air hose - NW5-Ø 8 mm
261 645
19
Quick release coupling for supplementary air hose - NW5-Ø 8 mm
261 637
Powder hose - 66 type, POE, Ø 16/11 mm, with conductive strip (standard)
105 139*#
Powder hose - 74 type, POE, Ø 15/10 mm, with conductive strip
1001 673*#
Powder hose - 75 type, POE, Ø 18/12 mm, with conductive strip
1001 674*#
* Please indicate length
# Wearing part
12 • Spare parts list
OptiFlow (type IG06)
V 08/13
OptiFlow Powder injector (type IG06)
16
17
18
19
18
7
6
B
A
8
8
9
9
5
13
11
4
3
12
11.1
4.1
10
1
2
OptiFlow Powder injector (type IG06)
OptiFlow (type IG06)
Spare parts list • 13
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement