OptiSpray F Manual coating equipment
Contents
1. Replace corresponding part or send in for repair Replace the 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 The objects are not properly grounded Press the selection key application key Replace the high volt age cascade or send in the gun for repair Check the grounding Control unit displays remain dark although the control 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 The powder is not flu idized Compressed air not pre sent 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 the throttle mo tor OptiSpray F Manual coating equipment Troubleshooting e 23 iTw Gema 24 e Troubleshooting V 02 09 Fault Causes Troubleshooting The manual gun does not spray powder al Compressed air not pre sent Check the compressed air supply though the control unit is switched on and the gun trigger is pressed Transport air not present Connect the control unit and the dense phase pump to the com pressed air Check the hose2. acquires fluid like characteristics The transport air 4 spraying air 5 fluidizing air 3 and electrode rins ing air 6 are provided by the OptiStar Control unit Filter regulating valve Dense phase pump m il Fluidized powder hopper function OptiSpray F Manual coating equipment Function description e 9 TvyGema yoe Scope of delivery OptiSpray F An OptiStar Control unit in a metal case with power sup ply cable An OptiSpray Dense phase pump A mobile trolley with a gun hose support A fluidized powder hopper An OptiSelect Manual powder gun with connection cable powder hose rinsing air hose diffuser and standard nozzle set see therefore the OptiSelect Manual powder gun user manual An electrically conducting powder hose 10 e Function description OptiSpray F Manual coating equipment V 02 09 Technical data iTw Gema OptiSpray F Manual coating equipment Electrical data OptiSpray F Manual coating equipment Nominal input voltage 100 240 VAC Frequency 50 60 Hz Input power 60 VA Nominal output voltage to the gun max 12 V Nominal output current to the gun max 1A Protection type IP54 Temperature range 0 40 C Control unit approval see the corresponding operating manual Dense phase pump approval see the corresponding operating manual Pneumatic data OptiSpray F Manual coating equipment Compress
3. Rectus connector NW 7 4 mm 1 4 a 256 730 7 Closure plug 8 mm 238 023 OptiSpray F filter regulating valve OptiSpray F Manual coating equipment Spare parts list e 29 irv Gema Re OptiSpray F powder hopper Powder hopper complete 1001 653 Bottom section complete incl pos 1 9 1001 644 1 Bottom plate 1001 640 2 Fluidizing plate 390 151 3 Fluidizing plate gasket 390 186 4 Clamp ring 390 194 5 Sealing ring 10 2 17x3 8 mm 230 626 6 Elbow screw connection 1 8 a 1 8 a 1001 079 7 Flowrestrictor 1 4 mm 371 912 8 Connector NW5 1 8 i 200 859 9 Protective strip 103 837 10 Hopper cover complete 1001 648 Suction tube complete L 504 mm pos 13 14 and 15 339 130 13 Suction tube holder incl pos 14 336 483 14 O ring Y 28 3x1 78 mm 224 987 15 Suction tube 336 491 Hose feedthrough complete incl pos 17 18 and 19 1006 049 17 Hose feedthrough 1006 032 18 O ring 16x2 mm 231 517 19 Connection fitting M16 1006 050 20 Locknut PG 21 234 869 Venting tube complete pos 22 28 1002 043 22 Venting tube 375 845 23 O ring 38x4 mm 239 151 24 Locknut 342 343 25 Double nipple 1 8 a 1 8 a 202 258 26 Ball valve 1 8 i 1 8 i 260 967 27 Throttle valve 1 8 a 1 8 a 1002 127 28 Connector NW5 1 8 a 237 272 Spiral hose 40 45 mm not shown 100 048 Please indicate length 30 e Spare par
4. connec tion of the control unit to the dense phase pump The automatic gun does not spray powder although the control unit is switched on Fluidization not running see above No external signal at the trigger adaptor see above see above Check the external sig nal OptiSpray F Manual coating equipment ge 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 OptiSpray F Manual coating equipment 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 indicated 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 hazardous location approval will be preserved that way The use of spare parts from other manufacturers will invalidate the ITW Gema guarantee conditions OptiSpray F Manual coating equipment Spare parts list e 25 iTw Gema 630 OptiSpray F spare parts
5. contaminated it must be dismantled and the fluidizing tube must be cleaned with compressed air Maintenance and cleaning of the filter regulating valve The filter regulating valve of the OptiSpray F Manual coating equipment measures and cleans the compressed air Here the main compressed air connection of the equipment is located Replacing the filter element Procedure 1 A E Go O OptiSpray F Manual coating equipment Vent the plant and the manual coating equipment Remove the drain screw and let run out the condensation water Unscrew the filter glass on the filter unit Unscrew the filter pad Replace the filter element Clean the filter glass on the inside and reinstall it in reverse order Maintenance and cleaning e 21 iTw Gema V 02 09 Troubleshooting General information Fault Causes Troubleshooting Power pack defective Replace the power pack Main valve defective Gun not connected Gun plug gun cable or gun cable connection defective Remote control on pow der gun defective Replace main valve coil Connect the gun Replace corresponding part or send in for repair Replace the remote control gun back cover Gun LED remains dark although the gun is triggered Gun plug gun cable or gun cable connection defective Gun plug gun cable or gun cable connection defective Remote control on pow der gun defective Replace corresponding part or send in for repair
6. list OptiSpray F Manual coating equipment complete 1005 610 1 Swivel wheel 50 mm 260 606 2 Cylinder ribbed Allen screw M10x20 mm galv 260 584 3 Bearing bolt 1000 453 4 Counter washer 1000 944 5 Oylinder ribbed Allen screw M8x16 mm galv 261 793 6 Snap ring A 25 237 094 7 Gun retainer 1003 076 8 Countersunk Allen screw M6x20 mm 1002 992 9 Countersunk Allen screw M6x40 mm 1002 953 10 Hose holder 1000 699 11 Hexagon shakeproof nut MG 244 430 12 Power supply extension 1 2 m 1002 636 13 Grounding cable complete 301 140 14 Dense phase pump spare parts kit consisting of 1005 255 Fuse 2 AT 221 872 Assembly tool complete 1005 058 15 Pinch valves spare parts kit consisting of 1005 256 Pinch valve hose 1004 405 Pinch valve fit up aid 1005 270 Short instructions for pinch valve change 1005 382 16 Filter element spare parts kit consisting of 1005 257 Filter element 3 um complete 1005 056 Short instructions for filter element change 1005 383 17 Grounding cable complete L 1200 mm 1006 077 18 Filter regulating valve unit see corresponding spare parts list 19 Pneumatic connection consisting of 1002 042 Quick release connection NW5 6 mm 200 840 Plastic tube 6 4 mm black antistatic not shown 1001 973 Nut with kink protection M10x1 mm 6 mm not shown 201 308 20 Diffuser see Op
7. Operating instructions and spare parts list OptiSpray Manual coating equipment Translation of the original operating instructions iTw Gema woe Documentation OptiSpray F Manual coating equipment Copyright 2006 ITW Gema GmbH 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 GmbH OptiFlex OptiTronic OptiGun EasyTronic OptiSelect OptiFlow and Su perCorona are registered trademarks of ITW Gema GmbH OptiStar OptiSpray OptiMatic OptiMove OptiMaster OptiPlus Multi Tronic 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
8. e e E e P e Eo ai Pe RE eee 13 Connection with manual gun 14 Connection with automatic powder gun 14 Preparation for etart up 15 Prepare the fluidized powder hopper ssssssssnsssssserrrnnseesernrnrnrnenssrrerennn 15 Switch on the boot 15 i um AE 15 OptiSpray F with manual oun 15 OptiSpray F with automatic gun 15 Color change 17 General information cerae en hinein 17 Maintenance and cleaning 19 D ily maintenance tai bnt 19 Weekly maimtenance nenn snannnnnar nn 19 If in disuse for several days rr 19 OptiSpray F Manual coating equipment Table of contents e 1 iTw Gema geg Powder hOS6 FINSING 1 5 ctt ti aree tte dene ge 19 e RIDERE 20 Cleaning the powder hopper sssssssrssssssssrnrrensseettnrrtnsrerettnnnrnnnensrtenn en 20 Cleaning the powder oun 20 Cleaning the diffUser 2 iim ridet rta reet ie dd 21 Maintenance and cleaning of the filter regulating valve sssssss 21 Replacing the filter element 21 Troubleshooting 23 General information 5 2 as Bean ha ankam 23 Spare parts list 25 Ord ring spare patrts 2 d rh ete ee pedet PR il 25 OptiSpray F spare partslist no nn ens 26 OptiSpray F spare parts riesana hrat reia eo a e aa a e Eaa i 27 OptiSpray F spare partslist nc nnnnnnnnnnnnnnno 28 OptiSpray F filter regulating valve sssse nano ncncnnnnnncncnns 29 OptiSpray F powder hopper ooooooococccccccccocoonononccnnncncnnonononnnnn
9. ed air main connection Quick coupling Max input pressure 10 bar Min input pressure 7 0 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 11 m3 h Technical data e 11 OptiSpray F Manual coating equipment rwGema 12 e Technical data V 02 09 Connectable guns OptiSpray F Manual coating equipment OptiSelect GMO2 connectable yes with diffuser OptiGun GA02 yes with diffuser and trigger adaptor PG1 PG2 A no TriboJet no Attention The OptiSpray F Manual coating equipment can only be used with the approved gun types Dimensions OptiSpray F Manual coating equipment Width 690 mm Depth 800 mm Height 1295 mm Weight 61 kg OptiSpray F Manual coating equipment T iTw Gema Start up and operation Connecting guide Check the compressed air connection from the filter regulat ing valve to the control unit the dense phase pump and the Airmover Connect the compressed air supply hose from the compressed air circuit directly to the main connection of the filter regulating valve Note 1 The compressed air must be free of oil and water 2 OptiSpray F Manual coating equipment 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 wit
10. for operation Switch on the OptiSpray Dense phase pump The coating procedure will be started by pressing the gun trigger Note The further start up procedure and operation of the OptiSpray F Manual coating equipment is explicitly described in the OptiStar CG07P Gun control unit operating instructions chapter Initial start up and Daily start up OptiSpray F with automatic gun 1 Press the ON power switch on the OptiStar Control unit The displays illuminate and the control unit is ready for operation Switch on the OptiSpray Dense phase pump The coating procedure will be started by an external potential free contact Note The further start up procedure and operation of the OptiSpray F Manual coating equipment is explicitly described in the OptiStar CGO06CP Gun control unit operating instructions chapter Initial start up and Daily start up OptiSpray F Manual coating equipment Start up and operation e 15 Color change General information oe iTw Gema When a color change takes place the individual components of the man ual coating equipment must be cleaned carefully Thereby all powder particles of the former color must be removed Procedure 1 Empty the fluidized powder hopper and clean it thoroughly 2 Clean the dense phase pump hoses Pull out the suction hose from the fluidized container Point the powder gun into the booth Press the gun trigger until no more powder exits 3 Point the sucti
11. g equipment is to be used for other purposes or other substances outside of our guidelines then ITW Gema GmbH should be consulted OptiSpray F Manual coating equipment General safety regulations e 3 rwGema V 02 09 3 Observance of the operating service and maintenance instruc tions specified by the manufacturer is also part of conformity of use The OptiSpray F 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 4 Start up i e the execution of a particular operation is forbidden until it has been established that the OptiSpray F Manual coating equipment has been set up and wired according to the guidelines for machinery 98 37 EG EN 60204 1 machine safety must also be observed 5 Unauthorized modifications to the OptiSpray F Manual coating equipment exempts the manufacturer from any liability from re sulting damage 6 The relevant accident prevention regulations as well as other generally recognized safety regulations occupational health and structural regulations are to be observed 7 Furthermore the country specific safety regulations must be ob served Product specific security measures 4 e General safety regulations OptiSpray F Manual coating equipment The installation work to be done by the customer must be carried out according to local regulations Before starting up the pla
12. h 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 2 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 Connect the spraying air hose to the output 1 3 and to the powder gun diffuser Connect the powder hose to the dense phase pump and to the powder gun diffuser Connect the mains cable to the 2 1 Power IN plug and fasten it Start up and operation e 13 iTw Gema vm Connection with manual gun Manual gun Filter regulating valve Fluidizing air Connection with manual gun Connection with automatic powder gun Ce A T F j qp y TA Trigger adapter Automatic powder gun Filter regulating valve Fluidizing air Connection with automatic powder gun 14 e Start up and operation OptiSpray F Manual coating equipment We iTw Gema Preparation for start up Start up Prepare the fluidized powder hopper 1 Install the Airmover 2 Fill in powder 3 Adjust the fluidization on the control unit Switch on the booth The coating booth is switched on according to the corresponding user manual OptiSpray F with manual gun 1 Press the ON power switch on the OptiStar Control unit The displays illuminate and the control unit is ready
13. nnnnnnn mener nnns 30 OptiSpray F powder hopper ssssssssssseseeeeen nennen 31 2 e Table of contents OptiSpray F Manual coating equipment vods iTw Gema General safety regulations This chapter specifies the fundamental safety regulations that must be followed by the user and third parties using the OptiSpray F Manual coating equipment These safety regulations must be read and understood before the OptiSpray F Manual coating equipment is used Safety symbols pictograms The following warnings with their meanings can be found in the ITW Gema operating instructions The general safety precautions must also be followed as well as the regulations in the operating instructions DANGER Danger due to live electricity or moving parts Possible consequences Death or serious injury WARNING N Improper use of the equipment 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 OptiSpray F 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 OptiSpray F Manual coatin
14. nt 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 Note For further security information see the more detailed ITW Gema safety regulations OptiSpray F Manual coating equipment oe iTw Gema About this manual General information This operating manual contains all the important information which you require for the working with the OptiSpray F 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 reciprocators booths powder gun control units powder guns etc should be referenced to their corresponding documents OptiSpray F Manual coating equipment About this manual e 5 oe iTw Gema Function description Field of application The OptiSpray F Manual coating equipment with fluidized powder hop per is designed exclusively for electrostatic coating with organic pow ders Any other use is considered as non conform The manufacturer is not responsible for any damage resulting from this the risk for this is as sumed by the user alone Typical characteristics High powder output Processing the powder from the fluidized powder hopper Quick and simple color change S
15. on hose and the conveying hose into the booth and clean them with the manual cleaning procedure of the dense phase pump see therefore the user manual of the OptiSpray Dense phase pump 4 Start the cleaning program of the control unit and blow through the suction hose with compressed air Point the powder gun into the booth and press the gun trigger 5 Prepare the manual coating equipment with new powder for OptiSpray F Manual coating equipment start up Color change e 17 T iTw Gema Maintenance and cleaning Note 2 Regular and conscientious maintenance increases the service life of 1 the manual coating equipment and provides for a longer continuous coating quality Daily maintenance 1 Clean the dense phase pump see therefore the dense phase pump user manual 2 Clean the powder gun see the corresponding operating manual Clean the diffuser 4 Clean the powder hose see therefore section Color change Weekly maintenance 1 Clean the powder hopper dense phase pump and powder gun 2 Checkthe grounding connection of the control unit 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 longer downtimes take place the powder hose has to be cleaned The procedure is described in section Color change OptiSpray F Manual coating equipment Maintenance and cleaning e 19 iTw Gema T Cleaning Cleaning the po
16. tiStar CGO7 P Control unit user manual 21 Spare parts kit MCO2 MFO2 P 1002 789 Fuse 4 AT 262 897 Fuse 2 AT 221872 Fuse 0 1 AT 229 520 22 Powder hose 11 4 7 mm 1005 097 26 e Spare parts list OptiSpray F Manual coating equipment T iTw Gema OptiSpray F spare parts OptiSpray F spare parts OptiSpray F Manual coating equipment Spare parts list e 27 iTw Gema TAT OptiSpray F spare parts list 23 Powder hose 9 6 6 mm 1001 102 24 Plastic tube 8 6 mm black antistatic 103 756 25 Rubber wheel 200 mm 260 592 26 Countersunk Allen screw M6x30 mm 1002 952 27 Handle bar 1002 623 28 Powder container see corresponding spare parts list 29 Rubber buffer 35x40 mm M8 211 664 30 OptiStar CGO7P Gun control unit complete see corresponding operating manual 31 OptiSpray DPPO1 Dense phase pump complete see corresponding user manual 32 OptiSelect Manual powder gun complete see corresponding user manual 33 OptiStar program table 1002 063 28 e Spare parts list Please indicate length OptiSpray F Manual coating equipment V 02 09 OptiSpray F filter regulating valve iTw Gema Filter regulating valve unit complete 1006 038 1 Fixing plate 1006 037 2 Filter regulating valve unit 1006 036 3 Countersunk head screw M4x8 mm 214 647 4 Elbow joint 1 4 8 2x2 mm 1006 035 5 Elbow connection 1 4 i 1 4 a 222 674 6
17. 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 s iTw Gema Table of contents General safety regulations 3 Safety symbols poictograms sse eene 3 Conformity Of USE tiro p RU d eer CH e e cetera 3 Product specific security measures sssssss eene 4 OptiSpray F Manual coating equipment sssssseessseerrensseeernrrrnreererrer rnn 4 About this manual 5 General information 4i are da EE dead 5 Function description 7 Field of applicatiol 2 2 5 tp eet Wunde 7 Typical characteristics ner nep ed Pee eee dd 7 OptiSpray F Manual coating equipment ssessesenessseeertnrrenrstesrtrnrrnnsersrtrnnrnnneeerrenn 8 ele iios crim dietam t deti a aeg 8 Optistar Control Unit outra tr tb 8 OptiSpray Dense phase pump sss 8 Fluidized powder hopnper ee 9 Scope E EE 10 Opts pray Putin iia eR otia a engen 10 Technical data 11 OptiSpray F Manual coating equipment ssssssnsnsssseeenrtrrresseerrrnnstesttrnrtnnnennsent 11 Electrical data EE 11 Pneumatic dala aio ete epe toe eat ar een 11 Connectable gris ecce aia 12 Dimensions ran E der n dando de Wad Ue AE P ER OUR ERAT 12 Start up and operation 13 Connecting guide ie L
18. ts list OptiSpray F Manual coating equipment T iTw Gema OptiSpray F powder hopper OptiSpray F powder hopper OptiSpray F Manual coating equipment Spare parts list 31
19. upplied ready for use OptiSpray F Manual coating equipment Function description e 7 rwGema OptiSpray F Manual coating equipment V 02 09 Structure OptiSpray F Manual coating equipment structure 1 2 3 4 5 6 7 OptiStar Control unit OptiStar Control unit OptiSelect Manual powder gun OptiSpray Dense phase pump Mobile frame with hand rail Fluidized powder hopper Filter regulating valve Swivel wheel Gun holder Hose holder Powder filler flap Rubber wheel Air consumption Airmover Powder suction hose Diffuser All information about the OptiStar Control unit will be found in the corre sponding enclosed documentation OptiSpray Dense phase pump All information about the OptiSpray Dense phase pump will be found in the corresponding enclosed documentation 8 e Function description OptiSpray F Manual coating equipment ee iTw Gema Fluidized powder hopper The fluidized powder in the powder hopper 1 will be aspirated by the dense phase pump The powder arrives to the diffuser 7 through the powder hose 2 and then to the gun The powder is charged electrostati cally in the gun nozzle In addition an electrostatic field will be created between the gun nozzle and the grounded object The charged powder spray remains adhered on the surface of the object The powder will be fluidized in the powder container by fluidizing air 3 forced through a porous plastic plate from below Thereby the powder
20. wder hopper 1 Disconnect the fluidizing air supply 2 Remove the suction hose 3 Remove the cover blow out with compressed air and clean with a clean dry brush and cloth 4 Clean the suction tube 5 Empty the remaining powder into a container 6 Clean the hopper and above all the hopper floor 7 Clean the hopper with a cloth 8 Reassemble the powder hopper e Note Refill the powder hopper shortly before reusing Never clean the powder hopper with solvents or water Cleaning the powder gun Frequent cleaning of the gun helps to guarantee the coating quality e 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 2 Clean the diffuser Weekly 3 Remove the powder hose from the connection 4 Remove the diffuser from the gun and clean it 5 Blow out the gun from the connection in flow direction with com pressed air 6 Clean the integrated gun tube with the provided gun brush 7 Blow through the gun with compressed air again 8 Clean the powder hose 9 Reassemble the gun and connect it e Note See therefore the user manual of the corresponding powder gun 20 e Maintenance and cleaning OptiSpray F Manual coating equipment vods iTw Gema Cleaning the diffuser 1 2 Dismantle the diffuser Blow off the diffuser with compressed air in the powder flow di rection If the diffuser is severely
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