OptiFlex L manual coating equipment - spare parts
Contents
1. Fault Causes Troubleshooting Power pack defective Replace the power pack if error is perma nent Main valve defective Replace main valve coil Gun not connected Gun plug gun cable or gun cable connection defective Remote control on powder gun defective Connect the gun Replace corresponding part or send in for repair Replace remote control gun back cover Rinsing air solenoid valve of flat jet nozzle defective Replace valve coil Rinsing air solenoid valve of round jet nozzle defective Replace valve coil Gun plug gun cable or gun cable connection defective Replace corresponding part or send in for repair Gun LED remains dark although the gun is triggered Gun plug gun cable or gun cable connection defective Remote control on powder gun defective Replace corresponding part or send in for repair Replace remote control gun back cover Powder does not ad here to object al though the gun is trig gered and sprays powder High voltage and current deactivated High voltage cascade defective Objects are not properly grounded Press the selection key application key Send in the gun for re pair Check the grounding OptiFlex L manual coating equipment Troubleshooting e 29 iTw Gema 30 e Troubleshooting V 05 10 Fault Causes Troubleshooting Control unit displays remain dark although the con2. OptiSelect manual powder gun All information about the OptiSelect manual powder gun will be found in the corresponding enclosed documentation OptiFlow injector All information about the OptiFlow injector will be found in the corres ponding enclosed documentation Fluidized powder hopper The fluidized powder in the powder hopper is sucked into the injector by means of the conveying air 1 red hose The powder air mixture reaches OptiFlex L manual coating equipment TON iTw Gema the powder gun through the powder hose 2 The powder is electrostati cally charged at the nozzle of the gun In addition an electrostatic field is created between the gun nozzle and the grounded object The charged powder spray remains adhered to the surface of the object The powder is fluidized by air forced through a porous plastic plate from below The powder acquires thereby fluid like characteristics The conveying air supplementary air and rinsing air are set on the con trol unit N npn nn png Hr rtt VANS Fluidized powder hopper function OptiFlex L manual coating equipment Function description e 15 rwGema Scope of delivery V 05 10 OptiFlex 1 L 16 e Function description A OptiStar control unit in a metal case with power supply cable A base with column and filter unit A fluidized powder hopper A plug in OptiFlow injector An OptiSelect manual powder gun with gun cable powder hose rinsing air
3. DIN VDE 0165 Setting up electrical equipment in locations in areas with danger of explosion Sources Carl Heymanns Verlag KG Luxemburger Strasse 449 5000 K ln 41 or from the appropriate employers association 2 Beuth Verlag GmbH Burgrafenstrasse 4 1000 Berlin 30 General secretariat Rue Br derode 2 B 1000 Bruxelles or the appro priate national committee 4 VDE Verlag GmbH Bismarckstrasse 33 1000 Berlin 12 OptiFlex L manual coating equipment General safety regulations e 9 iTw Gema Ji 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 ac cording to the local regulations before start up 10 o General safety regulations OptiFlex L manual coating equipment Wes iTw Gema About this manual General information This operating manual contains all the important information which you require for the working with the OptiFlex L manual coating equipment It will safely guide you through the start up process and give you refer ences and tips for the optimal use of your new powder coating system Information about the function mode of the individual system components booth gun control unit manual gun or powder inje
4. EN 292 1 EN 292 2 Machine safety EN 50 014 to EN 50 020 identical DIN VDE 0170 0171 Electrical equipment for locations where there is danger of explosion EN 50 050 Electrical apparatus for potentially explosive atmos pheres Electrostatic hand held spraying equipment 2 EN 50 053 part 2 Requirements for the selection installation and use of electrostatic spraying equipment for flammable mate rials Hand held electrostatic powder spray guns 2 EN 50 177 Stationary electrostatic spraying equipment for flamma ble coating powder 2 PR EN 12981 Coating plants Spray booths for application of organic powder coating material Safety requirements EN 60 529 identic al DIN 40050 IP Type protection contact foreign bodies and water protection for electrical equipment 3 EN 60 204 identic al DIN VDE 0113 VDE regulations for the setting up of high voltage elec trical 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 DIN VDE 0105 part 1 part 4 VDE regulations for the operation of high voltage equipment 4 General regulations Supplementary definitions for stationary electrical spray ing equipment DIN VDE 0147 part 1 Setting up stationary electrostatic spraying equipment 5
5. powder hopper with solvents or water Cleaning the OptiSelect manual powder gun Frequent cleaning of the gun helps to guarantee the coating quality e 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 com pressed 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 e Note paz aaas the user manual of the OptiSelect manual powder 26 e Maintenance and cleaning OptiFlex L manual coating equipment ye iTw Gema Maintenance and cleaning of the filter unit The filter unit on the OptiFlex L 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 2 3 4 5 Unscrew the filter glass on the filter unit Loose the cap screw Remove the complete filter element Replace the filter element Clean the filter glass on the inside and install it again OptiFlex L manual coating equipment Maintenance and cleaning e 27 iTw Gema V 05 10 Troubleshooting General information
6. 1 5 I o Q Q 1 I IT m o m Fo paw FP opa K po e N Pa x d pa l pl h 1 I I i K EE HIH y mae ee y Suction L pl L 1 I I Je 1 1 NE Fd lt A el ea ala 11 5 14 13 12 Adjust to 5 5 bar by 6 Nm h air con gt sumption Fluidizing air Z IN A Powder hopper M1 Motor throttle HF01 04 1 Electrode rinsing air E1 Input unit 3 10 l min Pneumatic diagram OptiFlex L OptiFlex L manual coating equipment Schematic diagrams e 31 TON iTw Gema Spare parts list Ordering spare parts ss s S When ordering spare parts for powder coating equipment please indicate the following specifications Type and serial number of your powder coating equip ment Order number quantity and description of each spare part Example Type OptiFlex L manual coating equipment Serial no 1234 5678 Order no 203 386 1 piece Clamp Y 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 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 i
7. hose and standard nozzle set see therefore the OptiSelect manual powder gun user manual Pneumatic hoses for conveying air red supplementary air black and fluidizing air black OptiFlex L manual coating equipment iTw Gema V 05 10 Technical data OptiFlex L manual coating equipment Electrical data OptiFlex L Mains input voltage 100 240 VAC Operating frequency 50 60 Hz Input power 40 VA Nominal output voltage to the gun max 12 V Nominal output current to the gun max 1A Protection type IP54 Temperature range 32 d F Approval pendent Pneumatical data OptiFlex L Compressed air main connection G1 4 female thread Max input pressure 10 bar Min input pressure while unit in operation 6 bar Max water vapor content of the compressed air 1 3 g m Max oil vapor content of the compressed air 0 1 mg m Max compressed air consumption 8 m h OptiFlex L manual coating equipment Technical data e 17 rwGema V 05 10 Connectable guns OptiFlex L connectable OptiSelect GMO2 yes OptiGun GA02 yes PG1 PG2 A yes no remote control TriboJet yes with adapter The gun type must be set on the control unit see therefore the corres ponding user manual Attention The OptiFlex L manual coating equipment can only be used with the specified gun types Dimensions OptiFlex L W
8. manual coating equip ment exempts 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 must be ob served Explosion protection Protection type Temperature class T6 zone 21 C 0102 Il 2 D IP54 T4 zone 22 Technical safety regulations for stationary electrostat ic powder spraying equipment 4 e General safety regulations 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 pur pose 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 mal function or damage to the control itself Before every start up check the equipment for operational safety regular servicing is essential Safety regulations BGI 764 and VDE regulati
9. nen 29 Schematic diagrams 31 Pneumatic diagram OptiFlex L e eee eee eee 31 Spare parts list 33 Ordering Spare parts ei ern en la Einen 33 OptiFlex L manual coating equipment spare part list nen 34 OptiFlex L manual coating equipment spare parts seen 35 OptiFlex L manual coating equipment spare parts list nee 36 OptiFlex L manual coating equipment spare parts nennen 37 OptiFlex L manual coating equipment powder hopper nenn 38 OptiFlex L manual coating equipment powder hopper msn 39 OptiFlex L filter nit 3 004 ciated ta nie gates et dites cerit ded do 40 2 e Table of contents OptiFlex L manual coating equipment TON 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 OptiFlex L manual coating equipment These safety regulations must be read and understood before the OptiF lex L manual coating equipment is used Safety symbols pictograms The following warnings with their meanings can be found in the ITW Ge ma 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 use of the equipm
10. Allen key wrench size 6 262 030 36 Plastic tube 8 6 mm black 103 152 Wearing part Please indicate length 34 e Spare parts list OptiFlex L manual coating equipment Gen iTw Gema OptiFlex L manual coating equipment spare parts OptiFlex L manual coating equipment spare parts OptiFlex L manual coating equipment Spare parts list e 35 iTw Gema Vane OptiFlex L manual coating equipment spare parts list 1 Gun retainer 1001 140 2 Mains cable L 5m 12 G Switzerland 382 493 Mains cable L 5m VII G Schuko Europe Russia etc 382 485 Mains cable L 5m 498 G USA Japan etc 382 507 Mains cable L 5m BS89 5 GB Africa etc 382 515 Mains cable L 5m SAA 3 Australia China etc 382 523 Pneumatic connection supplementary air complete incl pos 5 6 and 7 382 221 5 Nut with kink protection M12x1 mm Y 8 mm 201 316 Hose 8 6 mm black 103 756 Quick release connection NW5 8 mm black 261 637 Pneumatic connection conveying air complete incl pos 8 9 and 10 382 213 8 Quick release connection NW5 8 mm red 261 645 9 Plastic tube 8 6 mm antistatic 103 500 10 Nut with kink protection M12x1 mm Y 8 mm 201 316 11 Grounding cable complete 301 140 12 Protecting cap 206 474 13 Shakeproof Allen screw M8x12 mm 263 214 Pneumatic connection conveying air complete incl pos 8 9 and 10 382 230 14 Quick release conne
11. En Operating instructions and spare parts list Manual coating equipment OptiFlex Translation of the original operating instructions iTw Gema V 05 10 Documentation OptiFlex L manual coating equipment Copyright 2005 ITW Gema GmbH All rights reserved This publication is protected by copyright Unauthorized copying is prohi bited 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 SuperCoro na 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 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 GmbH makes no representations or warranties with respect to the contents or u
12. Power IN plug and screw iton e Note Close the 2 2 Aux output with the provided dust protection cap OptiFlex L manual coating equipment Start up and operation e 19 rwGema eis 9 i O A Filter unit zo il I es 000 15 14 13 12 Fluidizing air Injector Connecting guide overview Preparation for start up Prepare the fluidized powder hopper 1 Release the clamp ring holding the cover and lift off complete with the injector and the venting hose from the powder hopper Take care that the suction tube is not damaged 2 Fill the hopper with max 2 dm 2 liters of powder Do not over fill because the fluidized powder can escape from the cover Carefully replace the cover and refasten the clamp ring Adjust the fluidization on the control unit see also the OptiStar CGO07 control unit operating instructions chapter Setting the flui dizing Switch on the booth The coating booth is switched on according to the corresponding user manual 20 e Start up and operation OptiFlex L manual coating equipment TON iTw Gema Start up Switch on the control unit 1 Press the ON power switch The display
13. ction NW5 4W 8 mm 203 181 15 Hose 8 6 mm black 103 756 16 Nut with kink protection M12x1 mm 8 mm 201 316 36 e Spare parts list Please indicate length OptiFlex L manual coating equipment Gen rwGema OptiFlex L manual coating equipment spare parts 14 7 OptiFlex L manual coating equipment spare parts OptiFlex L manual coating equipment Spare parts list e 37 iTw Gema Vane OptiFlex L manual coating equipment powder hopper Powder hopper complete incl pos 1 21 379 441 1 Hopper body 379 484 2 Base plate 379 492 3 Spacingring 382 191 4 Fluidizing bed 310 468 5 Cover 379 450 6 Suction tube holder complete incl pos 6 1 371 890 6 1 O ring 28 3x1 78 mm 261 564 7 Suction tube L 233 mm 371 939 8 Quick connection socket 379 468 9 Bezel Q 0 7 mm 371 904 10 Venting connector 12 mm 377 988 12 Clamping ring 160 05 258 237 13 Rubber pad 15x8 mm M4 A 234 915 14 O ring 15x1 5 mm 261 564 15 Sealing ring 10 2 17x3 8 mm 230 626 16 Countersunk head screw M5x16 mm 262 986 17 Lock nut PG29 262 056 18 Counter nut PG21 234 869 19 Connector NW5 1 8 200 859 20 Elbow screw connection 1 8 a 1 8 a 1001 079 21 Gasket 1003 657 38 e Spare parts list OptiFlex L manual coating equipment Gen iTw Gema OptiFlex L manual coating equipment powder hopper OptiFlex L manual coating equipm
14. ctor should be refe renced to their enclosed corresponding documents OptiFlex L manual coating equipment About this manual e 11 ys iTw Gema Function description Field of application The OptiFlex L manual coating equipment with fluidized powder hopper is designed exclusively for electrostatic coating with organic powders 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 The OptiFlex L electrostatic powder manual coating equipment with the OptiSelect manual powder gun is ideally suited for manual coating of ob jects in vary small series for test coatings at powder manufacturers and in test laboratories Typical characteristics Processing the powder from the fluidized powder hopper Quick and simple color change Supplied ready for use Available with one or two guns extensible OptiFlex L manual coating equipment Function description e 13 rwGema V 05 10 OptiFlex L manual coating equipment Structure 14 e Function description us OptiFlex L manual coating equipment structure 1 OptiStar control unit 6 Clamping element 2 OptiSelect manual powder gun 7 Pneumatic connection 3 Powder container 8 Filter unit 4 Injector 9 Tube 5 Rack 10 Base OptiStar control unit All information about the OptiStar control unit will be found in the corres ponding enclosed documentation
15. dized powder hopper sss see eee eee 14 STR LTO THT 16 OptiBlex TEL 2 nie neum tan bim ttp teen nee Tender ee Een nee 16 Technical data 17 OptiFlex L manual coating equipment 44444snsnennnnnennnnnnnennennnnennnnne 17 Electricalidata ii A rear 17 Pneumatical data 17 Conmectable JUAS 18 DIMENSIONS er DR e e e eed MN 18 Start up and operation 19 Connection g lde 1 2 taaan ansia 19 Preparation for Start Up ics 2 ii nere er tat e Pena RR MED eredi ta d 20 Prepare the fluidized powder hopper sese sese eee eee 20 Switch on the booth sese ee ee eee 20 iiri HEUTE 21 Switch on the control unit 21 OptiFlex L manual coating equipment Table of contents e 1 iTw Gema V 05 10 Color change 23 General information iia A da 23 Maintenance and cleaning 25 Daly Malta Ce iia a Hals 25 Weekly mainteriance reete e eet a e Li e eth eO He ie da ca 25 If in disuse for several days ssssssseeeee emen 25 Powder NOSe FINSING 2 oie tib tet erts tei grt etis eode bates 25 Cleaning M PH 26 Cleaning the powder Hopper esse sese eee ee eee eee 26 Cleaning the OptiSelect manual powder Qun sese sese eee eee 26 Maintenance and cleaning of the filter Un eee ee eee eee eee 27 Replacing the filter element sess 27 Troubleshooting 29 General information 24444444444400nnn nenn 795 s TER Tre TET 795 eN nn
16. ee 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 car ried 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 other wise 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 mach
17. ent powder hopper OptiFlex L manual coating equipment Spare parts list e 39 rwGema un OptiFlex L filter unit Filter unit complete without pos 14 1001 147 1 Filter separator MAF200L 8A 1007 321 2 T piece 1 4 i 1 4 a 1 4 i 262 064 3 Elbow joint 1 4 3x 8 8 mm 1007 327 7 Filter cartridge 20 um 1007 325 9 Manometer G1 4 0 10 bar 1007 328 10 Rectus nipple NW 7 4 1 4 a 256 730 11 Grommet 8 mm 238 023 12 Elbow joint 1 4 i 1 4 a 222 674 14 Rectus quick release connection for pos 10 NW 7 8 4W 10 mm 239 267 1 2 es t3 Za qual v e OptiFlex L filter unit 40 e Spare parts list OptiFlex L manual coating equipment Yo iTw Gema OptiFlex L manual coating equipment Spare parts list e 41
18. ent could damage the machine or cause it to malfunction Possible consequences minor injuries or damage to equip ment INFORMATION 1 Useful tips and other information Conformity of use 1 The OptiFlex L 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 L manual coating equipment is to be used for other purposes or other substances outside of our guidelines then ITW Gema GmbH should be consulted OptiFlex L manual coating equipment General safety regulations e 3 rwGema V 05 10 Observance of the operating service and maintenance instruc tions specified by the manufacturer is also part of conformity of use The OptiFlex L 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 in volved Start up i e the execution of a particular operation is forbidden until it has been established that the OptiFlex L manual coating equipment has been set up and wired according to the guidelines for machinery 98 37 EG EN 60204 1 machine safety must al so be observed Unauthorized modifications to OptiFlex L
19. hing cable green yellow must be connected to the earthing screw of the electrostatic powder spraying hand ap pliance The earthing cable must have a good metallic connec tion with the coating booth the recovery unit and the conveyor chain and with the suspension arrangement of the objects The electricity and powder supply to the hand guns must be set up so that they are fully protected against heat and chemical damage 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 The earthing of all electricity conducting devices e g hooks conveyor chains must be checked on a weekly basis The earth ing resistance must amount to maximally 1 MOhm The control device must be switched off if the hand gun is cleaned or the nozzle is changed When working with cleaning agents there may be a risk of ha zardous fumes The manufacturers instructions must be ob served when using such cleaning agents The manufacturers instructions and the applicable environmental requirements must be observed when disposing of powder lac quer and cleaning agents If any part of the spray gun is damaged broken parts tears or missing then it should not be used 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 sh
20. idth 654 mm Depth 310 mm Height 428 mm Weight 16 5 kg 18 e Technical data OptiFlex L manual coating equipment TON iTw Gema Start up and operation Connection guide 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 E Note 1 The compressed air must be free from oil and water 2 Connect the black hose for fluidizing air electrically conduc tive to the output 1 5 on the rear side of the control unit 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 Connect the gun cable plug to the socket 2 3 on the rear side of the control unit Connect the rinsing air hose to the electrode rinsing air out put 1 4 and to the powder gun Attach the injector connect the powder hose to the injector and to the powder gun Connect the red hose for the conveying air to the corres ponding output 1 2 on the rear of the control unit and to the injector Connect the black hose for supplementary air to the corres ponding output 1 3 on the rear side of the control unit and to the injector this hose is electrically conductive Connect the mains cable to the 2 1
21. inery found in the workplace ac cording to DIN VDE 0745 part 102 must be earthed 1 5 meters either OptiFlex L manual coating equipment ye iTw Gema 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 per sonnel 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 re pairs are made to the electronic parts or when the equipment is restarted so that there are additio
22. jector see therefore the user manual of the OptiFlow injector 2 Clean the powder gun see therefore the user manual of the Op tiSelect manual powder gun 3 Clean the powder hose see therefore in chapter Color change Weekly maintenance 1 Clean the powder hopper injector and powder gun 2 Check the control unit grounding connections to the coating booth the suspension devices of the work pieces or the con veyor chain If in disuse for several days 1 Remove 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 L manual coating equipment Maintenance and cleaning e 25 iTw Gema Vas Cleaning Cleaning the powder hopper 1 Disconnect the fluidizing air supply 2 Remove the injector Remove the cover blow out with compressed air and clean with a clean dry brush and cloth 4 Clean the suction tube and injector 5 Empty the remaining powder into a container 6 Vacuum the hopper and above all the floor of the hopper 7 Clean the hopper with a cloth 8 Reassemble the powder hopper o Note Refill the powder hopper shortly before reusing Never clean the
23. nal measures such as barriers to prevent unau thorized access Prohibition of unauthorized conversions and modifica tions 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 faul ty 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 work shops 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 ofthe coating area must conduct electricity normal concrete is generally conductive 4 The operating personnel must wear electricity conducting foot wear e g leather soles 5 The operating personnel should hold the gun with bare hands If gloves are worn these must also conduct electricity OptiFlex L manual coating equipment General safety regulations e 7 iTw Gema 10 11 12 13 14 15 16 V 05 10 The supplied eart
24. nvalidate the ITW Gema guarantee conditions OptiFlex L manual coating equipment Spare parts list e 33 iTw Gema Vane OptiFlex L manual coating equipment spare part list 1 Base complete 385 190 2 Filter unit complete see corresponding spare parts list 3 CGO7 gun control unit complete see corresponding operating manual 4 Powder hopper complete see corresponding spare parts list 5 OptiSelect manual powder gun complete see corresponding operating manual 6 Column complete 1002 532 7 Mounting bracket 1002 579 8 Rectus quick release connection 10 mm NW7 4 mm 239 267 A Clamping element 30 1 1 complete incl pos 9 10 11 376 183 9 Cover fix 364 720 10 Cover 364 010 11 Allen cylinder screw M8x25 mm 216 500 12 Allen ribbed screw M6x16 mm 261 823 13 Cleaning brush 12 mm 389 765 14 X Application cup complete see corresponding operating manual 15 Pneumatic connection conveying air complete 382 213 16 Pneumatic connection supplementary air complete 382 221 23 Pneumatic connection fluidizing air complete 382 230 25 Parts set consisting of 1002 016 Injector nozzle PTFE 377 724 Injector plug gauge 393 380 O ring 16x2 mm 231 517 Fuse F4 00AF 262 897 Cable tie L 100x2 5 mm 200 719 26 Rack complete 1002 680 27 Short instruction OptiStar CGO7 1002 060 28 Program table OptiStar CGO7 1002 063 32 Hex
25. ons DIN VDE 0147 Part 1 must be observed for safe operation Safety precautions specified by local legislation must be ob served The plug must be disconnected before the machine is opened for repair 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 OptiFlex L manual coating equipment TON iTw Gema 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 IFITW Gema powder spraying equipment is used in conjunction with machinery from other manufacturers then their safety regu lations must also be taken into account 10 Before starting work familiarize yourself with all installations and operating elements as well as with their functions Familiariza tion during operation is too late 11 Caution must be exercised when working with a powder air mix ture 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 elec
26. ould be used Repairs must only be carried out by specialists and under no cir cumstances should they be carried out in the operating area The former protection must not be reduced 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 powd er air concentration If the UEG is not known then a value of 10 g m 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 asso ciation BGV A1 General regulations BGV A2 Electrical equipment and material BGI 764 Electrostatic coating BGR 132 Guidelines for the avoidance of the dangers of ignition due to electrostatic charging Guideline Static Electrici ty 8 e General safety regulations OptiFlex L manual coating equipment V 05 10 iTw Gema VDMA 24371 Guidelines for electrostatic coating with synthetic powd er Part 1 General requirements Part 2 Examples of use EN European standards RL94 9 EC The approximation of the laws of the Member States relating to apparatus and safety systems for their in tended use in potentially explosive atmospheres
27. s illuminate and the control unit is ready for operation Note e The further start up procedure for the OptiFlex B manual coating 1 equipment is explicitly described in the OptiStar CG07control unit operating instructions chapter Initial start up and Daily start up OptiFlex L manual coating equipment Start up and operation e 21 yo iTw Gema Color change General information When a color change takes place the individual components of the ma nual coating equipment must be cleaned carefully Thereby all powder particles of the former color must be removed Procedure 1 Empty the powder hopper 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 Fitthe powder hose again to the hose connection on the injector 3 Dismantle and clean the powder gun see therefore the user ma nual of the OptiSelect manual powder gun 4 Clean the injector see therefore the user manual of the OptiFlow injector 5 Prepare the manual coating equipment with new powder for start up OptiFlex L manual coating equipment Color change e 23 TON iTw Gema Maintenance and cleaning Note gt Regular and conscientious maintenance increases the life span of 1 the manual coating equipment and provides for a longer continuous coating quality Daily maintenance 1 Clean the in
28. se 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 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 er iTw Gema Table of contents General safety regulations 3 Safety symbols pictograms seen 3 Confom OT USE ania e meet Reste o ure era PE patea 3 Technical safety regulations for stationary electrostatic powder spraying SQUIPIMEN Er Pm 4 General information sss eene 4 Safety conscious working sess emm ens 5 Individual safety regulations for the operating firm and or operating personnel ai nre ho tte a eu Eu 5 Notes on special types of hazard eee 6 Safety requirements for electrostatic powder coating 7 A summary of the rules and regulations eee eee eee eee 8 Product specific security measures e eee eee eee 10 About this manual 11 General information io 42a eine nenn 11 Function description 13 Field of application i Ree ei Re ei 13 Typical Ta nenne tevin ETE tous 13 OptiFlex L manual coating equipment see eee eee eee eee 14 Olrtct le roter er ore ftu n t one Mai Sonia ren ed 14 OptiStar control Unit iii atan tie ae 14 OptiSelect manual powder Qun sss eee eee eee 14 OPptElOWinjSctor a 2 cito tr Ho PRI PB De eiat anta 14 Flui
29. tions for the operating firm and or operating personnel 1 Any operating method which will negatively influence the tech nical safety of the powder spraying equipment is to be avoided OptiFlex L manual coating equipment General safety regulations e 5 iTw Gema 6 e General safety regulations V 05 10 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 operat ing instructions manual for specifying the dangers arising for hu mans 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 unders tandable 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 itis necessary the operating firm must ensure that the operating personnel wear protective clothing e g facemasks 7 The operating firm must guarant
30. trol unit is switched on Control unit is not con nected to the mains Power pack fuse defec tive Power pack defective Connect the equipment with the mains cable Replace the fuse Replace the power pack if error is perma nent The powder is not flui dized Compressed air not present Fluidizing air is set too low on the control unit Throttle motor defective Connect the equipment to the compressed air Set the fluidizing air cor rectly Replace throttle motor The gun does not spray powder al though the control unit is switched on and the gun is triggered Compressed air not present Injector throttle motor 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 Throttle motor defective Solenoid valve defective Front plate defective Connect the equipment to the compressed air Clean corresponding part Replace Insert the insert sleeve see above Replace the throttle mo tor Replace the solenoid valve Send in for repair OptiFlex L manual coating equipment V 05 10 Schematic diagrams Pneumatic diagram OptiFlex L iTw Gema Supplementary air Conveying air N
31. tromagnetic 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 unders tood 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 dan ger 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 au thorized personnel This applies to modifications to the electrical equip ment 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 regula
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