OptiFlex 2 B-en - ECE Canada Limited.
Contents
1. 41 OptiFliex2 B PneumatitgioUD rc rea aa 42 2 e Table of contents OptiFlex 2 B ia iTw Gema General safety regulations This chapter sets out the fundamental safety regulations that must be followed by the user and any third parties using OptiFlex 2 B manual coating equipment These safety regulations must be read and understood in full before the OptiFlex 2 B is put into operation Safety symbols pictograms OptiFlex 2 B 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 light injuries or damage to the equipment INFORMATION Useful tips and other information General safety regulations e 3 iTw Gema General Information General dangers 4 e General safety regulations V 06 11 2000 The OptiFlex 2 B 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 Any other use is considered non compliant The manufacturer shall not be liable for damage resulting from any such non compliant use2. and the user shall bear sole responsibility for such actions ITW Gema GmbH must be consulted prior to any use of the OptiFlex 2 B Manual coating equipment for purposes or substances beyond those stipulated in our guidelines Observance of the operating service and maintenance instructions specified by the manufacturer is also part of the conformity of use 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 also must be observed Additional safety and operation notices can be found on the accompanying CD or on the homepage www itwgema ch Start up is forbidden until it has been established that the OptiFlex 2 B manual coating equipment has been set up and wired according to the EU guidelines for machinery Unauthorized modifications to the OptiFlex 2 B Manual coating equipment exempt the manufacturer from any liability from resulting damages or accidents The operator must ensure that all users have received appropriate training for powder spraying equipment and are aware of the possible sources of danger Any operating method which will negatively influence the technical safety of the powder spraying equipment is to be avoided OptiFlex 2 B vr iTw Gema For your own safety only use accessories and attachments listed in the operating instructions The u
3. dust from the coating powder can cause respiratory issues or cause a slippage falling hazard The manual equipment may only be operated in conjunction with a sufficiently powerful suction unit such as Gema Classic Open booth 1 Turn on the gun control unit with the ON key The displays illuminate and the control unit is ready for operation Swivel aside the fluidizing suction unit Place the open powder container on the vibrating table WARNING If a container is placed on the vibrating plate then fingers caught in the gap between the two plates can be crushed The container may weight a max of 30 kg 4 Place the fluidizing suction unit onto the powder 5 Set coating parameters 6 Press the application button for the appropriate preset mode flat parts complicated parts KT overcoat The arrow above the desired button lights up OR 7 Press Ga program key a Select desired program 01 20 b Change coating parameters as required OptiFlex 2 B Initial start up e 23 iTw Gema Note 1 Programs 01 20 are preset at the factory but can be modified at any time after which they are automatically stored Fluidizing air 0 1 Nm h for OptiFlex B and S 8 Setting the total air volume ii KE correct powder cloud too little total air Note 1 A total air volume of 4 Nm h and a 50 powder share are recommended as the base values 9 Adjust the powder output volume e g acc
4. mm red 103 500 5 Pneumatic connection for supplementary air complete incl Pos 5 1 5 2 and 5 3 5 1 Quick release connection NW5 8 mm black 261 637 5 2 Nut with kink protection M12x1 mm 8 mm 201 316 5 3 Plastic tube 8 6 mm black 1008 038 6 Rinsing module complete See operating instructions OptiFlex 2 GM03 manual 1007 362 powder gun 7 Pneumatic connection for PowerClean air complete incl Pos 7 1 and 7 2 7 1 Quick release connection NW5 8 mm 1008 027 7 2 Plastic tube 8 6 mm black 103 152 8 Fluidizing suction unit complete 1007 509 9 Pneumatic connection for fluidizing air complete incl Pos 9 1 9 2 and 9 3 9 1 Quick release connection NW5 6 mm 200 840 9 2 Nut with kink protection M10x1 mm 6 mm 201 308 9 3 Plastic tube 6 4 mm black 1001 973 10 Pneumatic group complete see corresponding spare parts list 11 Quick release connection NW7 8 10 26 mm 239 267 12 Rubber damper 20x25 mm M6 2a 43sh 246 000 13 Hexagon shakeproof nut M6 244 430 14 Powder hose 15 10 mm 6m 1001 673 15 Brief instructions 1007 143 16 Operating manual 1007 141 Please indicate length 40 e Spare parts list OptiFlex 2 B vr iTyvGema OptiFlex 2 B manual coating equipment Spare parts 12 13 OptiFlex 2 B manual coating equipment Spare parts OptiFlex2B Spare parts list 41 iTw Gema OptiFlex 2 B Pneumatic group Pneumatic group compl
5. En Operating instructions and spare parts list Manual coating equipment OptiFlex 2 B Translation of the original operating instructions iTw Gema V 06 11 Documentation OptiFlex 2 B Copyright 2010 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 OptiFlex OptiTronic OptiGun EasyTronic EasySelect EasyFlow OptiStar OptiSelect OptiFlow and SuperCorona are registered trademarks of ITW Gema GmbH OptiMatic OptiMove OptiMaster OptiPlus PowerClean Precise Charge Control PCC 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 publication ITW Gema GmbH makes
6. For more on this please also review the user manual for the OptiFlex 2 GM03 manual powder gun 3 Clean the powder hose Please also review the section Color change Weekly maintenance 1 Clean fluidizing suction unit injector rinsing module and powder gun The fluidizing suction unit is placed back into the powder shortly before restarting operation 2 Check the control unit grounding connections to the coating booth the suspension devices of the work pieces or the conveyor chain If in disuse for several days 1 Separate from power mains 2 Clean the coating equipment 3 Turn off the compressed air main supply OptiFlex 2 B Cleaning and maintenance e 33 iTw Gema Cleaning A 34 e Cleaning and maintenance V 06 11 Powder hose rinsing If longer downtimes take place the powder hose has to be cleaned Procedure 1 Disconnect 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 Connect the powder hose again to the hose connection on the injector WARNING If no dust mask or one of an insufficient filter class is worn when cleaning the manual equipment then the dust that is stirred up from the coating powder can cause respiratory problems The ventilation system must be turned on for all cleaning work A dust mask corresponding to filter class FFP2 at minimum must be worn during any cleaning work Cleani
7. a Color change General information When a color change takes place the individual components of the manual coating equipment must be cleaned carefully All powder particles of the former color must be removed during this process The following describes an extreme color change light to dark 28 e Initial start up OptiFlex 2 B vr iTyvGema Remove and clean the nozzle 16 purge gun using air 22 23 OptiFlex 2 B Initial start up e 29 iTw Gema 30 Initial start up OptiFlex 2 B vr iTw Gema Shutdown 1 Release gun trigger 2 Switch off the control unit Note The adjustments for high voltage powder output electrode rinsing air and fluidizing remain stored If in disuse for several days 1 Separate from power mains 2 Clean the coating equipment see the corresponding operating manual 3 Turn off the compressed air main supply OptiFlex 2 B Initial start up e 31 var iTyvGema Cleaning and maintenance the OptiFlex 2 B manual coating equipment and provides for a longer continuous coating quality The parts which are to be replaced during maintenance work are available as spare parts These parts will be found in the corresponding spare parts list Note a Regular and conscientious maintenance increases the service life of Daily maintenance 1 Clean the injector see therefore the user manual of the OptiFlow injector 2 Clean the powder gun
8. d and familiar with the possible hazards involved Start up i e operation of its intended use is not allowed until it has been established that the OptiFlex 2 B manual coating equipment has been installed and wired according to the EU Machinery Directive 2006 42 EC EN 60204 1 machine safety must also be observed Unauthorized modifications to the OptiFlex 2 B manual coating equipment exempt the manufacturer from any liability from resulting 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 also must be observed Product specific safety measures Installation work performed by the customer must be carried out according to local regulations All components must be grounded according to the local regulations before start up OptiFlex 2 B manual coating equipment The OptiFlex 2 B manual coating equipment is a constituent part of the equipment and is therefore integrated in the system s safety concept If it is to be used in a manner outside the scope of the safety concept then corresponding measures must be taken Note 1 For further security information see the more detailed ITW Gema safety regulations 8 e General safety regulations OptiFlex 2 B ine iTyvGema About this manual General information OptiFlex 2 B This operat
9. directly from the original powder manufacturer s COMA arno orti eri rire iris sie lato 16 Freely rotating head piece 16 Start up 17 Preparation for start up 17 DASIGGONGIHIONS sella 17 SISI 6 REA ARR FREIRE RAR RT SIR IRR TRI 17 Mounting instructions 18 Connection iNstructions ui 19 Initial start up 21 SEL NEII f0 CORRE RARE ceases RR RR E E RR EA 22 Setting the device type i 22 Opeolola sndllalii aan 23 COM 23 Setting the background illumination 27 COloF chang e casiaarieale 28 General informati sauro iaia 28 Table of contents e 1 iTw Gema V 06 11 5 11016 OW N eie A AR A 31 Cleaning and maintenance 33 Dally MalMtenanC E ssena 33 VV CCKIY mantena nGE cortina road 33 TV GISUSETOF SEV El al CA Sie serieta 33 POWGEr NOSE MIMSIIAG ssa tatoo 34 CNS GINNING PR Re RE RE E I tig secre Aenean e A 34 Cleaning the fluidizing Suction UNIt 34 Cleaning the OptiFlex 2 GM03 manual powder gun 34 Maintenance and cleaning of the filter UNIt i 35 Replacing the filter eleMEnt 35 Troubleshooting 37 General informall0 isla 37 Spare parts list 39 Ordering spare Pallare elle aan 39 OptiFlex 2 B manual coating equipment Spare pattS rrenen 40 OptiFlex 2 B manual coating equipment Spare partS
10. eck the powder output 13 Check whether everything is functioning correctly Initial start up e 25 iTw Gema n 14 Coating 15 Adjust the coating parameters as necessary 16 Activate the rinsing function periodically Note It prevents the bridging phenomena that can lead to short circuiting 1 when handling powders such as metallic powders In moist or tropical environments any moisture is driven from the injector powder hose and powder gun a The LCD segments begin to move on the CG09 display O Note 1 The PowerClean function can be stopped as required using the P key a automatically SU e gt re 3 UL 2x manually b LU LL 4 Procedure Effect The automatic rinsing process is started Injector powder hose gun and spray nozzle are purged using compressed air The automated PowerClean function enables parallel cleaning of other components such as the fluid intake unit powder container etc automatic The operator controls the number and length of the PowerClean impulse by pressing the pistol trigger a second time After completion of the PowerClean procedure the controller switches back to coating mode 26 e Initial start up OptiFlex 2 B OptiFlex 2 B vr iTw Gema Setting the background illumination sel 1 Press key The display switches to the following level irv Gema gt 5 Select the desired brightness Initial start up e 27 iTw Gem
11. ete 1007 120 1 Filter cartridge 20 um 1007 325 OptiFlex 2 B Pneumatic group 42 Spare parts list OptiFlex 2 B ine iTyvGema OptiFlex 2 B Spare parts list e 43
12. fications Type and serial number of your powder coating equipment Order number quantity and description of each spare part Example Type OptiFlex 2 B 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 for this kind of bulk stock is always marked with an Wearing parts are always marked with a All dimensions of plastic hoses are specified with the external and internal 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 explosion protection will also be preserved that way The use of spare parts from other manufacturers will invalidate the ITW Gema guarantee conditions OptiFlex 2 B Spare parts list e 39 iTyvGema inni OptiFlex 2 B manual coating equipment Spare parts 1 CGO9 gun control unit complete see corresponding operating manual 1007 018 2 GMO3 manual powder gun complete see corresponding user manual 1008 070 3 1GO06injector complete see corresponding user manual 1007 780 4 Pneumatic connection for conveying air complete incl Pos 4 1 4 2 4 3 4 1 Quick release connection NW5 8 mm red 261 645 4 2 Nut with kink protection M12x1 mm 8 mm 201 316 4 3 Plastic tube 8 6
13. g up the OptiFlex 2 manual coating unit the following general conditions impacting the coating results must be taken into consideration Manual coating equipment is set up properly Gun control unit correctly connected Gun correctly connected Corresponding power and compressed air supply available Powder preparation and powder quality Set up The OptiFlex 2 B manual coating equipment should always be set up vertically on a flat surface WARNING The manual coating equipment must not under any circumstances be set up near a heat source such as an enameling furnace or an electromagnetic source such as a control cabinet If the manual equipment is being held by the bracket during maneuvering the fingers can potentially be crushed when the bracket is folded down onto the control unit OptiFlex 2 B Start up e 17 iTw Gema Mounting instructions The OptiFlex 2 B manual coating equipment must be set up in accordance with the setup and connecting instructions included with delivery Manual coating equioment OptiFlex 2 B 18 e Start up OptiFlex 2 B vr iTyvGema Connection instructions Maintenance unit Injector Fal mi PowerClean module 4 e amp Fluidizing suction unit Connection instructions overview The OptiFlex 2 B manual coating equipment must be connected in accordance with the setup and connection instructions Please also review the operating instructions for
14. his manual OptiFlow injector All information about the OptiFlow injector can be found in the corresponding enclosed documentation Product description e 15 iTw Gema n Scope of delivery OptiFlex 2 B OptiFlex 2 CGO9 control unit in a metal case with power supply cable mobile trolley with a gun hose support vibrating base and a fluidizing suction unit plug in OptiFlow injector OptiFlex 2 CM03 manual powder gun with gun cable powder hose rinsing air hose and standard nozzle set For more on this see the operating manual for the OptiFlex 2 CM03 manual powder gun Pneumatic hoses for conveying air red supplementary air black fluidizing air black and rinsing air black Operating manual Short instructions Typical properties Characteristics of the functions _ Processing the powder directly from the original powder manufacturer s container The OptiFlex 2 B manual coating equipment allows for powder to be processed directly out of the original powder manufacturer s container A titled vibrating floor has been included to ensure that the powder container empties itself completely Freely rotating head piece The OptiFlex 2 B manual coating equipment features a freely rotating and lockable head piece for more ergonomic operation and configuration Freely rotating head piece 16 e Product description OptiFlex 2 B RA iTw Gema Start up Preparation for start up Basic conditions When startin
15. hould only be removed when the power supply is switched off As far as it is necessary the operating firm must ensure that the operating personnel wear protective clothing e g facemasks A dust mask corresponding to filter class FFP2 at minimum must be worn during any cleaning work The operating personnel must wear electrically conductive steel toe footwear e g leather soles The operating personnel should hold the gun with bare hands If gloves are worn these must also conduct electricity These general safety regulations must be read and understood in all cases OptiFlex 2 B prior to start up General safety regulations e 7 iTw Gema Conformity of use V 06 11 The OptiFlex 2 B manual coating equipment is state of the art equipment that conforms to the recognized technical safety regulations and is designed for normal powder coating applications Any other use is considered non compliant The manufacturer shall not be liable for damages resulting from such use the user bears sole responsibility for such actions ITW Gema GmbH must be consulted before OptiFlex 2 B manual coating equipment is used for any other purposes or substances beyond those indicated here Observance of the operating service and maintenance instructions specified by the manufacturer is also part of conformity of use The OptiFlex 2 B manual coating equipment should only be used maintained and started up by trained personnel informe
16. ing manual contains all important information required to work with the OptiFlex 2 B manual coating equipment It will safely guide you through the start up process and give you references and tips for the optimal use of your new powder coating system Information about the functionality of the individual system components booth gun control unit manual gun or powder injector should be referenced to their enclosed corresponding documents About this manual e 9 var iTw Gema Product description Field of application The OptiFlex 2 B with powder box manual coating equipment is exclusively intended for electrostatic coating using organic powders For more on this please also review chapter Technical Data Any other use is considered non compliant The manufacturer is not responsible for any incorrect use and any associated risks are assumed by the user alone For a better understanding of the interrelationships in powder coating it is recommended that the operating instructions for all other components be read as well so as to be familiar with their functions too OptiFlex 2 B manual coating equipment Utilization The electrostatic OptiFlex 2 B manual coating equipment with the OptiFlex 2 GM03 manual powder gun is ideally suited for manual coating of objects OptiFlex 2 B Product description e 11 iTw Gema n Reasonably foreseeable misuse Operation without the proper training Use with insufficient compressed a
17. ir quality and grounding Use in connection with unauthorized coating devices or components Technical data Connectable guns OptiFlex 2 GM03 yes Warning The OptiFlex 2 B manual coating equipment can only be used with the specified gun type Powder output guide values General conditions for the OptiFlow Injector Powder type Epoxy polyester Powder hose mm 10 Conveying air nozzle mm Correction value CO 12 e Product description OptiFlex 2 B vr iTw Gema Guide values for OptiFlex 2 CG09 with the OptiFlow IG06 injector All values in these tables are guide values Differing environmental conditions wear and different powder types can affect the table values 3 Nm h 4 Nm3 h 5 Nm h Powder output g min 40 60 Total air Powder output amp 210 255 280 80 270 320 350 100 300 360 395 Air flow rates The total air consists of conveying air and supplementary air in relation to the selected powder quantity in As a result the total air volume is maintained constant i Factory Flow rate fluidizing air OptiFlex B 0 1 0 Nm8 h 0 1 Nm8 h Electrode rinsing air flow rate 0 3 0 Nm h 0 1 Nm h Flow rate total air at 5 5 bar 1 8 6 5 Nm h Note The total air consumption for the device is determined based on the 1 3 configured air values These values apply for an internal control pressure of 5 5 bar Electrical data
18. is resistance must be checked tested regularly when starting work The condition of the work piece attachments as well as the hangers must guarantee that the work pieces remain grounded The appropriate measuring devices must be kept ready in the workplace in order to check the grounding The floor of the coating area must conduct electricity normal concrete is generally conductive The supplied grounding cable green yellow must be connected to the grounding screw of the electrostatic manual powder coating equipment The grounding cable must have a good metallic connection with the coating booth the recovery unit and the conveyor chain respectively with the suspension arrangement of the objects Smoking and open flames are forbidden in the entire plant area No work that could potentially produce sparks is allowed OptiFlex 2 B No flash photography Separate from power mains before maintenance or repairs vr iTw Gema 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 Photographing with flashlight can lead to unnecessary releases and or disconnections by safety devices Disconnect the plugs before the machines are opened for maintenance or repair The plug connections between the powder spraying equipment and the mains s
19. k although the gun is triggered OptiFlex 2 B Gun not connected Connect the gun Contact local Gema representative Gun plug gun cable or gun cable connection defective Remote control on Contact local Gema powder gun defective representative Troubleshooting e 37 iTw Gema TN Powder does not The objects are Check grounding adhere to object improperly or reground at better although the gun is insufficiently grounded quality e and sprays High voltage and current Press the selection key MORA deactivated application key High voltage cascade Contact local Gema defective representative The powder is not Compressed air not Connect the equipment fluidized present to the compressed air Fluidizing air is set too Set the fluidizing air low on the control unit correctly Throttle motor defective Contact local Gema representative No electrode rinsing air Rinsing air throttle motor Contact local Gema defective representative Vibrator not functioning Vibrator condenser Contact local Gema broken representative Vibrator not plugged in plug in Incorrect equipment Configure parameter PO type configured See operating instructions for the OptiFlex 2 CG09 manual gun control unit Chapter Initial Start up Setting Equipment 38 e Troubleshooting OptiFlex 2 B ine iTyvGema Spare parts list Ordering spare parts When ordering spare parts for powder coating equipment please indicate the following speci
20. lter 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 OptiFlex 2 B Cleaning and maintenance e 35 Troubleshooting General information Note V 06 11 iTyvGema Prior to any troubleshooting measures always check whether the equipment parameters PO as configured in the control unit are correct See operating instructions for the OptiFlex 2 CG09 manual gun control unit Chapter Initial Start up Setting Equipment Type Control unit displays remain dark although the control unit is switched on The gun does not spray powder Control unit is not Connect the equipment connected to the mains with the mains cable Power pack fuse Replace the fuse defective Power pack defective Contact local Gema representative Compressed air not Connect the equipment present to the compressed air although the control unit is switched on and the gun trigger is pressed Gun LED remains Injector throttle motor or nozzle on injector powder hose or powder gun are clogged Clean the corresponding part Insert sleeve in the Replace injector is clogged Insert sleeve is not Mount insert sleeve installed Fluidization not running not running see seebelow oe air incorrectly ee total air correctly configured Default value 4 Nm h Main valve defective Replace main valve dar
21. ng the fluidizing suction unit 1 Remove the injector 2 Remove rinsing module 3 Remove the fluidizing suction unit 4 Clean the fluidizing suction unit with compressed air Also blow off the suction tube with compressed air on Clean the injector see therefore the injector user manual Clean rinsing module Reassemble the individual parts Cleaning the OptiFlex 2 GM03 manual powder gun Frequent cleaning of the gun helps to guarantee the coating quality Note Before cleaning the powder gun switch off the control unit The compressed air used for cleaning must be free of 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 OptiFlex 2 B vr iTw Gema 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 2 Note 1 Please also review the user manual for the OptiFlex 2 GM03 manual powder gun Maintenance and cleaning of the filter unit The filter unit on the OptiFlex B manual coating equipment measures and cleans the compressed air This is where the equipment s main compressed air connection is located Replacing the filter element Procedure 1 Unscrewthe filter glass on the fi
22. 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 Movenstrasse 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 vana iTyvGema Table of contents OptiFlex 2 B General safety regulations 3 Safety symbols PICTOGFAMS cccccccccssssseeececeeeceeeeseeeceeeeeseaeaeeeeeeeeessaaeaeeeeeeeesaas 3 COMO O USO senina ina Ea o aaa 8 Product specific safety MEASUres iii 8 OptiFlex 2 B manual coating EQUIPMENT 8 About this manual 9 GEneraliniofmalloii tsns tolse 9 Product description 11 FIeld 0LaPPlicalio nisi liei waensdesb Gants 11 Uiliza ion ssi 11 Reasonably foreseeable MISUSE 12 TFechnnicoldale nella il 12 Conneclabie guns trilli iaia 12 Powder output guide values 12 Guide values for OptiFlex 2 CG09 with the OptiFlow IGO6 injector 13 PAM ATIOW GANG Sanrio lies 13 Elecirical dala delega 13 Pneumalcdaldaarulclc lic 14 DIMensionS s lla 14 PFOGESSIDIE POWdErs s scie 14 Design and IUNGION ica 15 General WCW scars lie 15 Scope Of delivery i 16 OpiFiox2 Balilla 16 Typical properties Characteristics of the fUNCHIONS 16 Processing the powder
23. optfex B I Connection and output for vibrator on Aux 110 230 VAC output max 100 W a 24 VDC Connection for rinsing function valve Temperature range ie 32 F 104 F Max surface temperature 120 C 248 F Approvals C x Il 3 D IP54 120 C OptiFlex 2 B Product description e 13 iTw Gema TN Pneumatic data Input pressure Dynamic based on pressure 5 5 bar 80 psi regulator setting A water vapor content of the compressed 1 3 g m Max oil vapor content of the compressed air 0 1 mg m Max compressed air consumption 8 Nm h Dimensions 14 e Product description i s sSSS Ci pti lex 2 B REA iTyvGema Design and function General view OptiFlex 2 B 13 16 OptiFlex 2 B manual coating equipment Structure 1 OptiFlex 2 CGO9 control unit 10 Filter unit 2 OptiFlex 2 GM03 manual powder gun 11 Gun holder 3 OptiFlow injector 12 Hose holder 4 Mobile frame with hand rail 13 PowerClean module 5 Fluidizing suction unit 14 Shelf 6 Vibrating table 15 Rubber wheel 7 Powder box 16 Swivel wheel 8 Swivel arm with guide sleeve OptiFlex 2 GM03 manual powder gun All information about the OptiFlex 2 CM03 manual powder gun can be found in the documentation for that equipment enclosed with this manual OptiFlex 2 CG09 control unit All information about the OptiFlex 2 CG09 manual gun control unit can found in the documentation for that equipment enclosed with t
24. ording to the desired coating thickness ODO much powder little powder 24 e Initial start up OptiFlex 2 B OptiFlex 2 B A vr iTw Gema Note To achieve maximum efficiency we recommend avoided an overly high powder volume where possible The standard setting of 50 and a total air volume of 4 Nm h is recommended at the start The total air volume is thereby kept constant automatically by the control unit If values are entered that the equipment cannot implement then the operator is informed of this by a blinking in the relevant display and a temporary error message 10 Setting the electrode rinsing air sel a Press the key The second display level will be shown ri l ge Di BB approx 0 1 Nm h approx 0 5 Nm h 11 Setting the fluidization too much electrode rinsing air sel a Press the key The second display level will be shown SU c Check the powder fluidization in the powder container The powder fluidization in the powder containers depends on the powder characteristics the humidity and the ambient air temperature Fluidizing and vibration start by switching on the control unit WARNING If the fluidization has been incorrectly adjusted then the coating powder can create a dust cloud capable of causing respiratory problems Ensure proper setting of fluidization 12 Point the gun into the booth not at the object to be coated press the gun trigger and visually ch
25. se of other parts can lead to risk of injury Only original ITW Gema spare parts should be used Repairs must only be carried out by specialists or by authorized ITW Gema service centers Unauthorized conversions and modifications can lead to injuries and damage to the equipment and invalidate the ITW Gema GmbH guarantee The connecting cables between the control unit and the spray gun must be installed so as to eliminate the possibility of damage during the operation Safety precautions specified by local legislation must be observed The plug connections between the powder spraying equipment and the mains should only be removed when the power supply is switched off All maintenance activities must take place when the powder spraying equipment is switched off dangers The powder coating equipment may not be switched on until the booth is in operation If the booth stops the powder coating device must switch off too The control units for the spray guns must be installed and used in zone 22 Spray guns are allowed in zone 21 Only original ITW Gema OEM parts are guaranteed to maintain the explosion protection rating If damages occur related to the use of spare parts from other manufacturers all relevant warranty or compensation claims are void 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
26. the OptiFlex 2 CG09 manual gun control unit 1 suspension arrangement Check ground connections with Ohm Note O Use clamp to connect grounding cable to the cabin or the meter and ensure 1 MOhm or less OptiFlex 2 B Start up e 19 iTv Gema ae Notes 1 The compressed air must be free of oil and water 20 e Start up OptiFlex 2 B iTw Gema Initial start up Note 1 If a malfunction occurs see the troubleshooting guide as well as the gun control unit operating manual Note The remainder of the start up procedure for the OptiFlex 2 GM03 manual powder gun is explicitly described in the operating instructions for the OptiFlex 2 CG09 manual powder gun control unit chapter Initial start up and Daily start up OptiFlex 2 B Initial start up e 21 iTw Gema n Set head piece Setting the device type Note If the control unit is delivered as a integral component of an 1 OptiFlex apparatus then the system parameters will have been factory preconfigured for optimal use For more on this please also see the operating instructions for the OptiFlex 2 CG09 manual gun control unit O NOTE 1 The manual gun control unit always starts up to the last configured settings 22 e Initial start up OptiFlex 2 B PRA iTw Gema Operation Coating WARNING If the manual equipment is not being used for coating in conjunction with a sufficiently powerful suction unit then the stirred up
27. ventilation available to prevent a dust concentration of greater than 50 of the lower explosion limit UEG max permissible powder air concentration If the UEG is not known then a value of 10 g m should be considered see EN 50177 Explosive danger All unauthorized conversions and modifications to the electrostatic spraying equipment are forbidden for safety reasons The safety devices may not be dismantled or put out of operation Mandatory operational and workplace notices from the operating company must be written in a comprehensible manner in the language of equipment operators and posted in a suitable location OptiFlex 2 B General safety regulations e 5 iTw Gema Slipping danger Strict compliance with grounding requirements No smoking or open flames 6 e General safety regulations V 06 11 Powder lying on the floor around the powder spraying equipment is a potentially dangerous source of slipping Booths may be entered only in the places designed for this purpose Static charges Static charges can have the following consequences Charges to people electric shocks sparking Proper grounding must be in place to prevent objects from becoming charged Grounding All electrically conductive parts found within 5 meters around each booth opening and in particularly the objects to be coated must be grounded The grounding resistance of each object must amount to maximally 1 MOhm Th
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