OptiFeed CA08 Fresh powder control unit - spare parts
Contents
1. ccccceceeeeeeeenneeeeeeeeeeeeeeeaaeaeeeeeeeeeeeesenaees 11 Start up and operation 13 CONMEGCHONS ie nennen near hehe denne 13 Gonnecling guide einen 14 PIN ssignment u a hear 15 SLU Disorder a 15 Troubleshooting 17 General information uri A AA adicta 17 Spare parts list 19 Ordering Spare Dari cocidas 19 OptiFeed CA08 Fresh powder control unit front plate ooooooccccnnnoccccnanoncnnnano 20 OptiFeed CAO8 Fresh powder control unit rear wall o ooooconoccccnonoccccnanoncnnnnno 21 OptiFeed CA08 Fresh powder control unit spare Parts ooconncninncccnnccnnacnnnccnnnannos 22 OptiFeed CA08 Fresh powder control unit spare Parts oooonncnincccnicccnnonnnonnnnanoos 23 OptiFeed CA08 Fresh powder control unit Table of contents e 1 as iTw Gema General safety regulations This chapter sets out the fundamental safety regulations that must be fol lowed by the user and third parties using the OptiFeed CA08 Fresh pow der control unit These safety regulations must be read and understood before the OptiFeed CA08 Fresh powder control unit 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 N Improper use2. 50 VA Type 2 Output 1 1 x 230 VAC 160 VA Output 2 1 x 230 VAC 50 VA Protection type control units IP54 A ATEX zone 22 rov ere CE Ex 113D Pneumatical Data OptiFeed CA08 Compressed air connection input out 3 8 a put Min input pressure 6 bar 87 psi Max input pressure 10 bar 145 psi Max water vapor content of the com 3 pressed air 1 3 g m Max oil vapor content of the compressed 0 1 mg m air 21 Nm h Total air consumption at 6 bar with PPO1 OptiFeed CA08 Fresh powder control unit Technical data e 9 rwGema Ge Dimensions OptiFeed CA08 Width 248 mm Depth 304 mm Height 178 mm Weight 6 1 kg 10 e Technical data OptiFeed CA08 Fresh powder control unit re Tu Gema Operating and display elements Displays and operating elements OptiFeed CA08 Fresh powder control unit operating and display elements Designation Function 1 Power switch 2 Transport air regulator 3 Pressure indicator OptiFeed CA08 Fresh powder control unit Operating and display elements e 11 re iTw Gema Start up and operation Connections OptiFeed CA08 Fresh powder control unit connections on the rear wall Connection Description 1 Power IN Mains cable connection 100 240 VAC 1 1 IN Compressed air input connection 7 10 bar 101 145 PSI 1 2 OUT Compressed air output connection 2 Interlock
3. of the equipment could damage the machine or cause it to malfunction Possible consequences minor injuries or damage to equip ment o INFORMATION 1 Useful tips and other information Conformity of use 1 The OptiFeed CA08 Fresh powder control unit is built to the lat est 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 OptiFeed CAO8 Fresh powder control unit is to be used for other purposes or other substances outside of our guidelines then ITW Gema AG should be consulted OptiFeed CA08 Fresh powder control unit General safety regulations e 3 iTw Gema V 01 07 Observance of the operating service and maintenance instruc tions specified by the manufacturer is also part of conformity of use The OptiFeed CA08 Fresh powder control unit should only be used maintained and started up by trained personnel who are informed about and are familiar with the possible hazards in volved Start up i e the execution of a particular operation is forbidden until it has been established that the OptiFeed CA08 Fresh pow der control unit has been set up and wired according to the guidelines for machinery 98 37 EG EN 60204 1 machine safety must also be observed Unau
4. screw M4x8 mm 215 139 3 Button 28 mm 200 069 4 Nut M14x1 mm 302 163 5 Pressure regulator 1 4 6 6 239 852 6 Pressure gauge 1 8 a 0 10 bar 243 620 7 Connection sleeve 1 8 i 6 mm 233 412 8 Illuminated push button with lock yellow 262 820 9 Fixing flange 262 838 10 LED module 230 V yellow 262 846 11 Standard auxiliary switch 1s 262 854 12 Adhesive seal strip 9x2 mm 100 250 13 Cap screw 35x12 mm 1003 955 OptiFeed CA08 Fresh powder control unit front plate 20 e Spare parts list OptiFeed CA08 Fresh powder control unit ae srw Gema OptiFeed CA08 Fresh powder control unit rear wall 1 Interlocking connection complete 1003 939 2 Vibrator connection complete 1003 940 3 Fuse holder long 200 131 4 Fuse F 2 5 AT not shown 206 571 5 Power supply connection complete 1003 938 OptiFeed CA08 Fresh powder control unit rear wall OptiFeed CA08 Fresh powder control unit Spare parts list e 21 iTw Gema Ge OptiFeed CA08 Fresh powder control unit spare parts 1 Compressed air hose 10 17 mm black 105 147 2 Hose clamp 17 25 mm 223 085 3 Hose connection 8 mm 203 165 4 Threaded sleeve 3 8 i 203 157 5 Double nipple 1 2 a 3 8 a 244 317 6 Solenoid valve 1 2 NW 13 5 mm 230 VAC incl pos 6 1 259 500 6 1 Valve coil 230 VAC for pos 6 1001 158 7 Connection fitting 1 2 a 3 8 a 223 794 8 Valve cable complete
5. 0 3 m incl pos 8 1 393 061 8 1 Cap screw M3x35 mm 219 932 9 Connection plug 3 8 a 1d6 203 173 10 Pressure regulator 3 8 244 384 11 Elbow joint 1 8 a 6 mm 254 061 12 T piece 3 8 a 3 8 i 3 8 i 223 310 13 Elbow joint 3 8 a 6 mm 267 120 14 Connection fitting 3 8 a 3 8 a 202 975 15 Hexagon nut 1 8 SW 14 1003 953 16 Fluidizing pad 1 8 a 237 264 17 _ Condenser MFD2 400 V device type 1 237 540 18 Condenser MFD8 400 V device type 2 1003 941 22 e Spare parts list OptiFeed CA08 Fresh powder control unit ae iTw Gema OptiFeed CA08 Fresh powder control unit spare parts OptiFeed CA08 Fresh powder control unit spare parts OptiFeed CA08 Fresh powder control unit Spare parts list e 23
6. En Operating instructions and spare parts list OptiFeed CA08 Fresh powder control unit rw Gema Ya Documentation OptiFeed CA08 Fresh powder control unit Copyright 2006 ITW Gema AG All rights reserved This publication is protected by copyright Unauthorized copying is pro hibited by law No part of this publication may be reproduced photocop ied 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 AG OptiFlex OptiTronic OptiGun EasyTronic EasySelect OptiFlow and SuperCorona are registered trademarks of ITW Gema AG OptiStar OptiMatic OptiMove OptiMaster OptiPlus MultiTronic and Gematic are trademarks of ITW Gema AG 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 con cerned approve of or are bound in any form by this manual We have en deavored to retain the preferred spelling of the trademarks and regis tered trademarks of the copyright holders To the best of our knowledge and belief the information contained in this publication was correct and valid on the date of issue ITW Gema AG makes no representations or warranties with respect to the contents or use of this publication and reserves the
7. If a powder shortage occurs the OptiControl control unit switches a contact which turns on the solenoid valve for transport air as well as the vibrator motors at the powder container and the powder sieve The fresh powder now will be transported to the powder hopper 2 Adjust the air pressure to the powder pump with the regulator and check it on the pressure gauge The powder volume depends on the powder condition as well as the hose length between the container and the pow der hopper If the hopper is full the powder supply as well as both vibrator motors are switched off by the OptiControl control unit If no fresh powder is present the control unit re leases an alarm after a preselected time Note For detailed information about the OptiControl control unit function please see the corresponding user manual OptiFeed CA08 Fresh powder control unit Start up and operation e 15 iTw Gema V 01 07 Troubleshooting General information Fault Causes Troubleshooting No fresh powder avail able Put a new powder con tainer on the FPS Vibrator motor not run ning Vibration control switch not switched on Vibration control fuse defective Motor cable is not con nected to vibration con trol Switch on Replace Connect Fresh powder is not extracted Transport air is not set correctly Nozzle check valve or powder pump injector clogged Fluidizing suction unit clogged Flu
8. Interlocking connection 3 Motor 1 Vibration motor connection 1 4 Motor 2 Vibration motor connection 2 F1 Mains fuse OptiFeed CA08 Fresh powder control unit Start up and operation e 13 iTw Gema Ge Connecting guide 1 Check the compressed air connection from the filter unit to the control unit Connect the compressed air supply hose to the 1 1 IN main connection o Note 1 The compressed air must be free from oil and water 2 Connect the transport air hose to the output 1 2 OUT on the rear side of the control unit 3 Connect the vibration motor cable to the sockets 3 and 4 on the rear side of the control unit 4 Connect the interlocking signal cable to the socket 2 on the rear side of the control unit 5 Connect the mains cable to the 1 Power IN plug and fasten it OptiControl interlocking lt Powder hopper T i 7 Vibrator 1 Connecting guide overview 14 e Start up and operation OptiFeed CA08 Fresh powder control unit as iTw Gema Pin assignment Connection 1 Power IN 1 N Neutral conductor power supply 2 L Phase 200 240 VAC E P Ground Connection 2 Interlock 1 L OUT 2 L IN Connection 3 Motor 1 Connection 4 Motor 2 1 Motor connection U 2 Motor connection V 3 Motor connection W E Ground PE 1 Switch on the OptiFeed CA08 Fresh powder control unit with the power switch 1 The powder level is monitored by a level sensor in the pow der hopper
9. erenced to their corresponding documents OptiFeed CA08 Fresh powder control unit About this manual e 5 as iTw Gema Function description Field of application The OptiFeed CA08 Fresh powder control unit is designed exclusively for the control of the PPO1 or PPO2 Powder pumps as well as the two vibra tor motors on the powder transport Any other use is considered as non conform The manufacturer is not re sponsible for any damage resulting from this the risk for this is assumed by the user alone For a better understanding of the interrelationships in powder transport it is recommended to read completely the operating instructions of the other components so as to be familiar with their functions too OptiFeed CA08 Fresh powder control unit Typical characteristics The OptiFeed CA08 Fresh powder control unit transports the coating powder from a container to the powder hopper The control unit is a part of the powder transport consisting of the OptiControl CM03 CM10 CM20 control unit the PPO1 or PPO2 Powder pump as well as the FPS Fresh pow der system The OptiFeed CA08 Fresh powder control unit is integrated into the Gema OptiFlex A2 control cabinet and is supplied there with compressed air and mains voltage Basic functions OptiFeed CA08 Fresh powder control unit Controlling of the powder pump transport air by a regulator on the front side of the device Monitoring of the air pressure and therefore of the
10. idizing air bezel clogged Transport hose clogged Check and adjust Clean replace if neces sary Clean Clean replace if neces sary Clean OptiFeed CA08 Fresh powder control unit Troubleshooting e 17 T iTw Gema 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 OptiFeed CA08 Fresh powder control unit Serial number 1234 5678 Order no 203 386 1 piece Clamp 18 15 mm When ordering cable or hose material the required length must also be given The spare part numbers of this yard meter ware is always marked with an The wear parts are always marked with a All dimensions of plastic hoses are specified with the external and inter nal diameter Example 8 6 mm 8 mm outside diameter 0 d 6 mm inside diameter i d WARNING Only original ITW Gema spare parts should be used because the hazardous location approval will be preserved that way The use of N spare parts from other manufacturers will invalidate the ITW Gema guarantee conditions OptiFeed CA08 Fresh powder control unit Spare parts list e 19 iTw Gema V 01 07 OptiFeed CA08 Fresh powder control unit front plate 1 Front frame complete 1000 393 2 Cylinder
11. powder quantity on the manometer Controlling of the vibrator motors by the OptiControl control unit in dependence of the powder level in the powder hopper On the rear wall a connection is located each for a vibration motor at the powder container and on the powder sieve Function description e 7 iTw Gema Ge Device types The OptiFeed CA08 Fresh powder control unit is delivered in two types depending on the installed fresh powder system and its vibration motor The two device types differ only in the capacity of the inserted condens ers For the FPS11 Fresh powder system a vibrator of 160 VA e g is used In this case a condenser adapted for the higher performance will be in stalled in the equipment OptiFeed CA08 Type 1 Type 2 Serial number 16401 xxxxx 16402 xxxxx Connection and performance of the vibrators 230 VAC 50 VA 230 VAC 160 VA Output 1 Output 2 230 VAC 50 VA 230 VAC 50 VA Order number of the vibrators Output 1 237 582 258 628 Output 2 237 582 237 582 8 e Function description OptiFeed CA08 Fresh powder control unit Technical data V 01 07 iTw Gema OptiFeed CA08 Fresh powder control unit Electrical data OptiFeed CA08 Nominal input voltage 200 240 VAC Frequency 50 60 Hz Input power value 200 VA Temperature range operation 0 40 C Vibrator connection and performance Type 1 Output 1 and 2 2 x 230 VAC
12. right to revise this publication and make changes to its content without prior notice Printed in Switzerland ITW Gema AG M venstrasse 17 9015 St Gallen Switzerland Phone 41 71 313 83 00 Fax 41 71 313 83 83 E Mail info itwgema ch Homepage www itwgema ch ie iTw Gema Table of contents General safety regulations 3 Safety symbols piCLOYLAMS ooonnnocinncnnicccnnnonannnccncanccnnrncn nora cnc 3 Conformity Of USC ooocccccnccconocononcccccnncnn no nn narran rr 3 Product specific security measures comcncccnnnnccnnocnnnncccnoncnnnnnn nano cnn nnrnnnncnnnncin 4 OptiFeed CAO8 Fresh powder control unit ooooococnnnnccccnonocccnnonononcnnnannncnos 4 About this manual 5 General information ooocconoccccnonoccncnononcncnonononnccnnonnncnnnonnnccnnn rn nccnnn nn nr annt nn n rca nrnncnnnnss 5 Function description 7 Fiod o applicate ea an ida 7 OptiFeed CA08 Fresh powder control unit 0 cceceececseeeeeeeeceeeeeseeeeesaeeeeeeeeeaees 7 Typical characteristics 20044rnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnen 7 Basic functions eeens eeii aae en anai aeee aa E NEE ERKENE EE 7 Device tYPBScooonoccconncconocinononcna noc nro 8 Technical data 9 OptiFeed CA08 Fresh powder control unit 0 c cceeceeeeeeeeeeeeeeeeeeeeseeeeeeaeeeeeeeeeaees 9 Gere Ike a aa aaa aaa A 9 Pneumaiical Dada aca 9 A een A AI IEA A NE N 10 Operating and display elements 11 Displays and operating element
13. thorized modifications to OptiFeed CA08 Fresh powder control unit exempts the manufacturer from any liability from re sulting damage The relevant accident prevention regulations as well as other generally recognized safety regulations occupational health and structural regulations are to be observed Furthermore the country specific safety regulations must be ob served Explosion protection Protection type Temperature class T6 zone 21 C 0102 x II 2 D rae T4 zone 22 Product specific security measures 4 e General safety regulations OptiFeed CA08 Fresh powder control unit The OptiFeed CA08 Fresh powder control unit is a constituent part of the system and is thus integrated into the safety system of the plant For the use outside of the safety concept corresponding measures must be taken For further information see the more detailed ITW Gema safety regu OptiFeed CA08 Fresh powder control unit T iTw Gema About this manual General information This operating manual contains all the important information which you require for the working with the OptiFeed CA08 Fresh powder control unit 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 sys tem Information about the function mode of the individual system components reciprocators booths powder gun control units powder guns etc should be ref
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