OptiFlex B manual coating equipment - spare parts list
Contents
1. 14 Back cover complete 1000 617 14 1 Printed circuit board holder complete incl pos 14 2 1002 029 14 2 Radial gasket 1000 795 14 3 Shield complete 1002 028 14 4 Cap screw M3x8 mm not shown 202 363 15 Hose connection complete for internal hose 11 12 mm 1001 340 Hose connection complete for internal hose 9 10 mm 1002 030 15 2 O ring 12x1 5 mm 1000 822 16 Hook replaceable 1000 877 17 Countersunk head screw M4x8 mm plastic 263 516 18 PT screw 1000 843 19 Threaded sleeve complete 1000 948 20 Flatjet nozzle complete 1000 047 20 1 Electrode holder complete 1000 055 20 2 Flatjet nozzle 1000 049 OptiSelect adaptor for PGC control unit not shown 1001 952 Cleaning brush 2 12mm 389 765 Parts set not shown consisting of 1002 359 Round jet nozzle NSO2 complete 382 922 Cable clamp 303 070 Deflector plate 16 mm 331 341 Deflector plate 24 mm 331 333 Deflector plate 32 mm 331 325 Hose connection complete for internal hose 2 11 12 mm 1001 340 O ring 12x1 5 mm 1000 822 Countersunk head screw M4x8 mm plastic 263 516 Powder hose 10 mm not shown 1001 673 Powder hose 2 11 mm not shown 105 139 OptiFlex B manual coating equipment Spare parts list OptiSelect e 51 jueuudinbe Bunpo jenuew g x l indo sndo 151 Sued ZG X3 1V pe oudde ed jou 8L 6001 my d 021 0001 seoue ooejins oDue OL2. 2 Check the grounding connections of the coating booth the sus pension devices of the work pieces or the conveyor chain Cleaning Cleaning the OptiSelect Manual powder gun Frequent cleaning of the gun serves to guarantee the quality of the coat ing e Note 1 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 powder hose from connector 3 Remove the spray nozzle from the gun and clean it with com pressed air 4 Blow through the gun with compressed air beginning from the connection in flow direction 5 Clean the integrated gun tube with the supplied brush if neces sary 44 Maintenance and cleaning OptiFlex B manual coating equipment iTyvGema 6 Blow through the gun again with compressed air 7 Clean the powder hose 8 Reassemble the gun and connect it Attention Cleaning the OptiSelect Manual powder gun with the following sol vents is not allowed Ethylene chloride acetone ethyl acetate methyl ethyl ketone me thylene chloride premium gasoline turpentine tetrachloromethane toluene trichloroethylene xylene Note Only cleaning agents vvith a flash point of a least 5 Kelvin above the 1 ambient temperature or cleaning places with technical ventilation are allowed Cleaning the spray nozzles Daily or after every shift
3. 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 32 e Spare parts list OptiStar CG07 OptiFlex B manual coating equipment m iT Gema OptiStar CG07 Manual gun control unit OptiStar 07 Manual gun control unit complete 1001 060 1 Front plate see corresponding spare parts list 2 Housing and power pack see corresponding spare parts list 3 Rear wall see corresponding spare parts list 4 Protective cover 1004 426 3 OptiStar CGO7 Manual gun control unit 4 OptiFlex B manual coating equipment Spare parts list OptiStar CG 7 e 33 iTyvGema Manual gun control unit outside rear vvali OptiStar CGO rear wall complete aluminum version 1000 063 OptiStar CGO7 rear wall complete steel version 1004 500 1 Rear wall aluminum version 1000 067 Rear wall steel version 1004 175 OptiStar 07 vibrator connection assembled 1001 177 Milled nut M6 200 433 4 Hose connection complete 6 4 mm aluminum version 1001 520 Hose connection complete 6 4 mm steel version 1004 184 5 Hose connection complete 8 6 mm aluminum version 1001 519 Hose connection complete 8 6 mm steel version
4. Clean the inside and outside of the spray nozzle with compressed air Never immerse the parts in solvents Check the seating of the spray nozzles Make sure that the threaded sleeve is always tightened well If the spray nozzle is not completely tight the dan ger exists that the high voltage of the gun can flash over which can lead to damage to the powder gun Weekly Remove the spray nozzles and clean inside with com pressed air If sintering should have formed then this is to be removed Monthly Check the spray nozzles for wear The flat jet nozzle is to be replaced if the spray pattern is no longer a regular oval deeper grooves in the nozzle slot or even the wall thick ness is no longer visible the wedge of the electrode holder is worn down Nozzles with deflectors if the wedge of the electrode holder is worn down then the electrode holder is to be replaced OptiFlex B manual coating equipment Maintenance and cleaning e 45 iT Gema V 05 10 Troubleshooting guide General information 46 e Troubleshooting guide H11 error message on control unit Gun LED remains dark although the gun is triggered Powder does not ad here to object al though the gun is trig gered and sprays powder Gun not connected Gun plug or gun cable defective Remote control on pow der gun defective High voltage adjustment is set too low Gun plug or gun cable defective LED on gun defective High volta
5. 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 V 05 10 Table of contents General safety regulations OptiFlex B Technical data Stan OL LDU Maintenance and cleaning Spare parts list OptiFlex B OptiStar CG07 Technical atana d aaa Start up and operation Spare parts list OptiStar 07 OptiSelect Manual powder gun Technical Data Start up and operation Maintenance and cleaning Troubleshooting guide Spare parts list OptiSelect OptiFlovv IG02 type Cleaning and maintenance Troubleshooting guide Spare parts list OptiFlovv OptiFlex B manual coating equipment iT Gema Table of contents e 1 m iTw Gema General safety regulations Safety symbols pictograms s P The following wa
6. e c Various functions can be remotely controlled with the and keys on the back side of the powder gun OptiSelect gun type Adjust the powder output by pressing the or key on the gun The powder output will be increased or decreased ac cordingly Change application modes Preset mode Program mode by w N Z pressing the and keys on the gun at the same time The change takes place counterclockwise Check by observing the key LEDs on the control unit e Note By pressing one of the keys the preset values display will be shown Shut down The shut down of the OptiStar CGO7 Manual gun control unit takes place in following steps 1 Remove the powder gun trigger 2 Switch off the control unit 3 Switch off the Airmover OptiFlex F e Note The adjustments for high voltage powder output electrode rinsing air and fluidizing remain stored If in disuse during several days 1 Remove the mains plug 2 Clean the coating equipment see the corresponding operat ing manual 3 Turn off the compressed air main supply Saving programs e Note The values in programs 1 20 and the 3 preset application modes are saved automatically without confirmation 28 e Start up and operation OptiFlex B manual coating equipment V 05 10 Error diagnosis of the softvvare General information iT Gema The correct function of the OptiStar 07 Manual gun control unit is con stantly monitored If the equipment so
7. 1004 183 6 Rectus quick release connection complete aluminum version 1001 517 Rectus quick release connection complete steel version 1004 181 Gun connection CGO7 assembled 1001 179 Mains connection 07 1001 176 Cap screw M3x8 mm 202 363 10 Cap screw M3x12 mm not shown 216 747 Shock protection is fixed on the rear wall not shown 1001 058 11 Fixing screws for shock protection 2 pieces M5x12 mm 216 348 Corona Tribo adapter not shown 1001 869 Protection cap for 2 2 Aux connection not shown 206 474 Connecting cable power supply for 2 control units operation not shown 1001 867 34 e Spare parts list OptiStar CG07 OptiFlex B manual coating equipment m iTw Gema Manual gun control unit outside rear wall 11 10 8 2 Aluminium version T 9 1 3 4 6 5 Steel version Manual gun control unit outside rear wall OptiFlex B manual coating equipment Spare parts list OptiStar CG07 e 35 iTw Gema T OptiStar CG07 Manual gun control unit rear wall 1 Pneumatic group complete 1001 029 2 Throttle motor completely assembled 1000 064 3 Main solenoid valve cable 07 1001 410 4 Spring washer M3 R 201 880 o Hexagon nut M3 202 142 6 Cylinder screw M3x16 mm 221 074 7 Screw in nipple 1 8 6 mm OR 240 095 8 Fluidizing pad 1 8 a 237 264 9 Gasket steel version only 1003 528 10 Cap screw K SL M4x16 mm steel version only 216 801 11 O Ring 8
8. 73x1 78 mm steel version only 248 428 Aluminium version e T I a R r s 4 f ae bu tu A 7 f fi SALT 4 27 3 LT Steel version 36 e Spare parts list OptiStar CG07 OptiFlex B manual coating equipment iT Gema OptiStar CG07 Manual gun control unit housing and power pack 1 Housing 07 control unit aluminum version 1001 435 Housing 07 control unit steel version not shown 1004 200 2 Power pack 15 VDC 374 059 3 Power pack connection cable assembled 1000 388 4 Connection cable assembled 1001 178 o Standoff 4 4 8 4 8 mm PA 263 508 OptiStar CGO7 Manual gun control unit power pack and housing OptiFlex B manual coating equipment Spare parts list OptiStar CG 7 e 37 iTw Gema OptiStar CG07 Manual gun control unit front plate Front plate complete 1000 395 1 Front plate with foil keyboard 1000 394 3 OptiStar mainboard V1 0 complete with display 1000 875 4 Locknut M3 262 498 5 Washer Q 3 2 7x0 5 mm 201 944 6 Standoff 6x3 4x6 5 mm 1001 925 7 Standoff 6x3 4x15 5 mm 1001 926 8 Compression spring 0 5x6 3x13 5 mm 230 251 9 Special screw 1000 400 38 e Spare parts list OptiStar CG T OptiFlex B manual coating equipment iTyvGema OptiSelect Manual powder gun Scope of delivery OptiSelect Manual powder gun OptiFlex B manual coating equipment An OptiSelect Manu
9. is created in the cavity see figure below This vacuum causes powder to be drawn up the suction tube and into the cavity A powder air mixture is created The forward air velocity at the nozzle conveys the powder air mixture through to the powder hose to the gun Conveying air Supplementary air Insert sleeve to the powder gun LE D ed mixture Vacuum Powder hopper j l 55 Suction tube q e e o o o o o b o ee ee b o o o o o o 6 98 o o o o se e o o o o o o To o o e o o S o o o o o e o e e o o o e ee o o o o 8 o o o e o o o e o e o o o o ee e The concentration of the powder air mixture and with it the powder out put depends on the conveying air pressure and supplementary air pres sure the quality of the powder the length of the powder hose the diame ter of the powder hose the number of coils in the hose the difference in the height between the gun and injector and the type of nozzle The OptiFlow IG02 type e 59 iT Gema V 05 10 condition of the insert sleeve is of great importance because wear cau ses the powder output to sink drastically Experience with pneumatic material handling technology s
10. volume The display indicates the powder output in 9o and total air volume in m h 6 Press the corresponding key for the rinsing air on the control unit according to the nozzle used 7 Check the remote control by pressing the or key on the back of the powder gun and the modified powder output va lue is displayed on the control unit By simultaneous pressing of the and key the application modes can be changed on the control unit 42 e Start up and operation OptiFlex B manual coating equipment iTw Gema When all the checks are positive the gun is ready for operation Note f a malfunction occurs see the troubleshooting guide as vvell as the gun control operating manuall Svvitch on the control unit 1 Press the ON povver svvitch on the control unit The displays illuminate and the control unit is ready for operation Note e The next procedure for starting up the OptiSelect Manual powder gun is explicitly described in the OptiStar CG07 Gun control unit operating instructions chapter Initial start up and Daily start up OptiFlex B manual coating equipment Start up and operation 43 iTyvGema vun Maintenance and cleaning e Note Regular and conscientious maintenance increases the operating life of the unit and ensures a longer more constant coating quality Daily maintenance 1 Clean the gun see chapter Cleaning Weekly maintenance 1 Clean the gun see chapter Cleaning
11. 2 953 10 Countersunk Allen screw M6x20 mm 1002 992 11 Handle bar 1002 623 12 607 gun control unit complete see corresponding user manual 13 Hose holder 1000 699 14 Hexagon shakeproof nut M6 244 430 Cable connection fitting for vibrator cable M16 1 6 10 5 mm brass not shown 265 780 17 Cable plug 4 pins male 206 466 18 Countersunk Allen screw M x30 mm 1002 952 19 Grounding cable complete 301 140 20 Plastic hose 2 8 6 mm 103 756 21 Vibrator motor 220 240 VAC 50 Hz 1001 748 Vibrator motor 120 VAC 389 382 22 GO2 V Injector complete see corresponding user manual 23 Gun retainer 1003 076 24 Spare parts set MBO2 consisting of 1002 015 Insert sleeve PTFE 377 724 Injector plug gauge 393 380 Fluidizing pad 1 8 a 237 264 O ring 16x2 mm 231 517 Fuse 4 AT 262 897 Fuse 2 AT 221 872 Fuse 0 1 AT 229 520 Cable tie L 100x2 5 mm 200 719 25 Ribbed cylinder screw M10x20 mm 260 584 26 Hexagon ribbed cylinder screw 8 16 mm 261 793 2 Short instruction sheet OptiStar CGO7 1002 060 28 Program table sheet OptiStar CGO7 1002 063 OptiFlex B manual coating equipment Spare parts list OptiFlex B e 15 iT Gema OptiFlex B manual coating equipment spare parts list 29 Filter unit complete see corresponding spare parts list 30 Snap ring A 25 237 094 Please indicate length 19 29 22 21 OptiFlex B manual coating equipment spare parts list 16 Spare parts lis
12. 5 mm Typ 1008 Material PUR 111 16 mm Typ 1004 Material PVC OptiFlex B manual coating equipment Fast color change standard Fast color change low powder flow Fast color change high powder flow Boron Nitride pow der low powder flow Used on previous equipment Enamel powder Used on previous equipment 2 11 16 mm 2 10 15 mm 2 12 18 mm 2 9 5 12 5 mm 2 11 16 mm 2 11 16 mm 2 12 20 mm 1001 673 1001 674 103 705 100 080 POE POE PVC PVC iT Gema special applica tions special applica tions flexible powder ho se flexible powder ho se Spare parts list OptiSelect e 55 jueuudinbe Bunpo jenuew g x l indo sndo 1si Sued leds e 9G S SOU WW ZL LL p pnioul si Buu o Ove LOOL 10 10 99UU0D s sou WW QL 6 40 2 UuO SOH pepnjour s 1 0 0 2001 M9IAJ9AO SJ0 29UUOO SOU JopMOd 01 80 A Va iT Gema Miscellaneous parts Adapter for Ea sySelect gun 1004 552 1002 069 1004 564 PGC Gun control gt OptiSelect gun 1001 952 1001 869 L 6m 1002 161 L 14m 1002 162 800 254 OptiFlex B manual coating equipment Spare parts list OptiSelect e 57 iTyvGema OptiFlow 1G02 type Principle of the injector and influence of supplemen tary air OptiFlex B manual coating equipment If air flows through the nozzle into the cavity a vacuum
13. IN J0J Aeids e 9pIM JO 9 Zzou jel ye Vel 0001 D13IN uo40g u13 jed Aeids pajbuy d p S HIAR pue spul u do sse229iJ 104 V 9 COOL 6 0001 m t xx N SLL 0001 im ubisap ulo sn 104 604N 670 0001 lzzou 170 0001 804 80 M9IAJ9AO S lZZOU zej 129 9 130 521 055 29 sapmod Jenueyw 33 sndo 01 80 A BUDE Ly iT Gema OptiSelect round jet nozzles overview w Deflectors t 16 mm 331 341 50 mm 345 822 For large flat sur NS02 face areas 378 518 NS02 382 914 382 922 1000 948 OptiFlex B manual coating equipment Spare parts list OptiSelect e 53 jueuudinbe Bunpo jenuew g x l indo j2ejesndo 151 Sued leds e pg r 6001 cvy 6001 8G6 966 076 96 J0joejoeg XX m m xx ww 92 025 6001 615 001 LEG 96 Z6 96 Keads ej4 x n unu sz o 0c v6e ELL 762 B 890 2001 290 2001 997 LOOL 098 87 S9 816 ww Qr ww og 71 POE TO 00 1 Te 091 1 ae suoisuajxe uno euoJ053Jedng pue suolsu x unb 1 4 0L S0 A 12 18 mm Typ 75 11 16 mm Typ 1001 Material PUR 11 16 mm Typ 66 Typ 74 Material POE Material POE V 05 10 Powder hoses overview 10 15 mm Material POE 9 5 112
14. Quick reference guide OptiFlex Manual coating equipment Translation of the original operating instructions iTyvGema vun Quick reference guide OptiFlex B manual coating equipment O 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 OptiTronic OptiGun EasyTronic EasySelect OptiFlow and Super Corona 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 use of this publication
15. al powder gun with gun cable 6 m Rinsing air hose 6 m Flat jet nozzle complete Round jet nozzle with deflector kit 16 24 and 32 mm Cable binder with Velcro closure Gun cleaning brush Spare parts kit OptiSelect Manual powder gun e 39 iTw Gema Technical Data OptiSelect Manual powder gun Electrical data OptiSelect Manual powder gun Ignition protection Ex 2 mJ T6 T 0 C 40 C emperature range 32 F 104 F Max operating temperature 85 C 185 F Approvals C x 120 5 5007 Attention The OptiSelect Manual powder gun can be connected to the OptiS tar and the OptiTronic without remote control control units 40 Technical Data OptiFlex B manual coating equipment iTyvGema Start up and operation Connecting guide 1 Connect the compressed air supply hose from the com pressed air circuit directly to the filter unit main connection on the rear side of the equipment connecting 1 4 BSP male thread The compressed air connection from the filter unit to the control unit must be connected Note 1 The compressed air must be free from oil and water 2 OptiFlex B manual coating equipment Connect the black hose for fluidizing air to the output 1 5 on the rear side of the control unit Connect the grounding connection cable to the control unit with the grounding screw and connect the 5 m long ground ing cable with the clamping clip to the boo
16. and serial number of your powder coating equipment Order number quantity and description of each spare part Example Type OptiFlex C Manual coating equipment Serial number 1234 5678 Order no 203 386 1 piece Clamp 2 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 hazardous location approval will be preserved that way The use of spare parts from other manufacturers will invalidate the ITW Gema guarantee conditions 48 Spare parts list OptiSelect OptiFlex B manual coating equipment iTyvGema OptiSelect Manual powder gun spare parts list Remarks 1 Ifa part of the gun body should be broken or the high voltage cascade in the gun body should be defective then the whole gun body is to be sent in for repair and check 2 f the powder gun cable is defective it is to be completely sent in for repair OptiSelect Manual powder gun complete A negative polarity incl gun cable 6 m rinsing air hose 6 m flat jet nozzle brush 1002 100 and parts kit without powder hose OptiSelect Manual powder gun c
17. antled or put out of operation The operating and job instructions has to be written in an understandable form and in the language of the persons employed and has to be an nounced in a suitable place in the working area Powder lying on the floor around the powder spraying equipment is a po tentially dangerous source of slipping Booths may be entered only in the places suitable for it Slip hazard ib OptiFlex B manual coating equipment General safety regulations e 5 iTw Gema Static charges Static charges can have the following consequences Charges to people electric shocks sparking Charging of objects must be avoided by a pro per grounding Grounding All electricity conducting parts found in the workplace of 5 meters around each booth opening and particularly the objects to be coated have to be grounded The earthing resistance of each object must amount to maxi mally 1 MOhm This resistance must be checked tested regularly when starting work The condition of the work piece attachments as well as the hangers Observe the l l i grounding regulations 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 electrosta
18. ating equipment OptiStar CG07 19 iTw Gema Technical Data OptiStar CG07 Manual gun control unit Connectable guns OptiStar CG07 connectable OptiSelect GMO2 yes OptiGun GAO2 only with trigger adapter PG1 yes PG2 A PG2 AX only with trigger adapter TriboJet yes with adapter The gun type must be adjusted reference chapter Additional options The Tribo gun is not type approved ATEX Only for enamel powder the gun is not type approved ATEX Attention The OptiStar CG07 Manual gun control unit can only be used with the specified gun types Electrical data Mains input voltage Operating frequency Input power without vibrator Nominal output voltage to the gun Nominal output current to the gun Vibrator connection and power on the Aux 110 220 VAC output max 100W Protection type IP54 Temperature range 77 32 F 104 F Max operating temperature 85 C 185 F Approvals C II 2 3 D PTBO5 ATEX 5009 20 e Technical Data OptiFlex B manual coating equipment V 05 10 iT Gema Start up and operation Connections b 10 Bai 87 145 PSI OptiStar CGO7 Manual gun control unit connections on the rear wall Connection 1 1 Air Supply IN 2 2 Aux OptiFlex B manual coating equipment Description Compressed air connection 6 10 bar 87 145 PSI Mains cable connection 100 240 VAC Vibration motor connection for OptiFlex B Gun cab
19. behavior of the flu idizing air Device type Fluidizing device OptiFlex F Box device OptiFlex B Stirrer device OptiFlex S Manual unit with fluidization OptiFlex S Fd Note AUX output function Always Off no vibration Vibration On during trig gering delay of 1 minute after releasing gun trigger The key T16 switches the vibration On and Off Stirrer On when gun trig gered Stirrer On when gun trig gered Fluidizing air function Fluidizing air is controlled by two different methods Turning on the fluidization key T16 will feed air to the hopper until key is turned off Triggering the gun is turn ing on the fluidization too fluidization can be turned off with key T16 Fluidizing air is switched On parallel by the trigger It runs after for 1 minute The key T16 switches the fluidization On and Off parallel to the vibration No fluidization no function of key T16 Fluidization is switched On and Off with trigger The key T16 switches Off the fluidization it can only be turned On by pressing the key again The system parameter PO of the manual unit may not be set on 3 automatic unit A wrong parameterization leads to various malfunctions Preparing the powder hopper container Prepare the powder hopper or powder box according to manual equip ment type OptiFlex F B S L etc reference the operating manual for the equipment type being used OptiFlex B
20. daily correction value is larger than 100 Daily correction value too large The theoretical value for convey ing air falls below minimum Total air is smaller than mini mum Main solenoid valve error con nection cable from main sole noid valve to basic electronics is missing check main solenoid valve Reduce supplementary air value or increase conveying air value to balance air volume to injector and clear help code Reduce conveying air value or increase supplementary air va lue to balance air volume to in jector and clear help code Reduce powder output Reduce daily correction value Limit conveying air to conveying air minimum Start up and operation e 29 iTyvGema k High voltage No oscillation cable broken os Replace gun cable cascade etc Gun error cillator or gun defective Power supply Remedy Power pack defective or over Replace the power pack if error 25 loaded is 7 Povver pack defective or over Replace the povver pack if error loaded i is 77 i Power pack defective or over Replace the power pack if error loaded is permanent Power pack defective or over Replace the power pack if error 2 loaded is 7 i EEPROM equipment memory Undervoltage 15V supply EEPROM error Load factory settings initialize EEPROM see there EEPROM content invalid fore in chapter RAM reset Timeout during EEPROM writing EEPROM error Values not co
21. ent Spare parts list OptiFlow 67
22. ftware determines a fault an error message is indicated with an error code Following is monitored High voltage technology Air technology Power supply Help codes The error diagnosis codes error codes are shown in the display A5 The error codes are stored in an error list in the order of their occurrence Each error in the list must be individually acknowledged with the keys T10 or T11 The error codes are shown with the format Hnn whereby nn is the nu meric code if necessary with a leading zero The errors are displayed in the order of their occurrence The keys T10 and T11 cannot be used for other functions as long as an error code is shown on A5 Here is the complete listing of all error codes possible for the OptiStar CGO07 Manual gun control unit Pneumatics Trigger valve main solenoid valve Supplementary air volume too high total air setting on display Conveying air volume too high powder 96 setting on display Powder output higher than 10076 Conveying air range lovver de viation OptiFlex B manual coating equipment Solenoid coil current lovver than preset limiting value Valve defective main board or cable defective The preset value for supplemen tary air is too high compared to your conveying air setting The preset value for conveying air is too high compared to your supplementary air setting The povvder output mul plied vvith the povvder hose length fac tor and the
23. ge and current deactivated High voltage cascade defective Objects are not properly grounded Connect the gun Replace corresponding part or send in for repair Replace remote control gun cap Increase high voltage Replace defective part or send in for repair Replace gun back cover Check the high voltage and current setting Send in the gun for re pair Check the grounding OptiFlex B manual coating equipment V 05 10 The gun does not spray povvder al though the control unit is switched on and the gun is triggered OptiFlex B manual coating equipment Compressed air not pre sent Too little conveying air Injector or nozzle on the injector powder hose or powder gun clogged Insert sleeve in the in jector worn or not in serted Nozzle in the injector clogged Fluidizing not running No conveying air Motor throttle defective Solenoid valve defective Front plate defective iTw Gema Fault elimination Connect the equipment to the compressed air Increase the powder output and or total air volume on the control unit Clean corresponding part Replace or insert Replace see above Replace the motor throt tle Replace the solenoid valve Send in for repair Troubleshooting guide e 47 iTyvGema T Spare parts list OptiSelect Ordering spare parts When ordering spare parts for powder coating equipment please indicate the following specifications Type
24. hows that pneumatic transport of fine solid matter powder in the form of tubing hose the transporting medium requires a certain volume of air per unit of time If a 11 mm hose is used this value is approximately 4 m h To decrease the powder output the vacuum in the cavity has to be reduced For that purpose the pressure of the conveying air is also reduced With the reduction of the conveying air the volume of air in the powder hose sinks to below the optimum value of 4 m h The powder transport be comes irregular so called pumping takes place In order to prevent this from happening supplementary air is added until the volume of the air in the powder hose is 4 5 m h once more This takes place fully automati cally with the OptiTronic control unit Powder volume setting table for OptiFlow injector OptiStar OptiTronic L 60 OptiFlovv 1602 type In order to set the ideal powder volume on the OptiStar OptiTronic it is recommended to select the firmness of the povvder cloud or the total air first As a guide value for different powder hoses the following values can be assumed Powder hose 1004 internal 2 11 mm 4 5 m h Powder hose 1005 internal 2 12 mm 5 6 m h According to the prevailing conditions powder powder hose layout the parts to be coated a low to lowest total air can also be set with the stan dard hose 1004 11 mm If a very large powder output is required it is recommended to
25. icate the following specifications Type and serial number of your powder coating equipment Order number quantity and description of each spare part Example Type OptiFlex B manual coating equipment Serial number 1234 5678 Order no 203 386 1 piece Clamp 2 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 N explosion protection will also be preserved that way The use of spare parts from other manufacturers will invalidate the ITW Gema guarantee conditions 14 e Spare parts list OptiFlex B OptiFlex B manual coating equipment V 05 10 iT Gema OptiFlex B manual coating equipment spare parts list 1 Wheel shaft 1000 453 2 Rubber wheel 200 mm 260 592 3 Lock washer 26 mm 1000 944 4 Swivel wheel 50 mm 260 606 5 Spacing ring 375 624 6 Rubber damper 20x25 mm M6 2a 43sh 246 000 7 Hluldizing suction unit see corresponding spare parts list 8 Stop plate 1000 513 9 Countersunk Allen screw M6x40 mm 100
26. le connection Fluidizing air connection Electrode rinsing air connection Supplementary air connection Ce Conveying air connection ca Grounding connection Start up and operation e 21 iT Gema 22 Start up and operation V 05 10 Connection guide 1 Note Check the compressed air connection from filter unit to con trol unit Connect the compressed air supply hose from the compressed air circuit directly to the filter unit main connec tion on the rear side of the equipment 1 4 female BSP The compressed air must be free from oil and water 2 Note 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 Insert the injector connect the powder hose to the injector and to the powder gun Connect the red hose for conveying air to the corresponding output 1 2 on the rear side of the control unit and to the injec tor Connect the black hose for supplementary air to the corre sponding output 1 3 on the rear side of the cont
27. ly by the control unit 2 Check the powder fluidizing in the hopper and ensure you have a small simmer or very low boiling action 3 Point the gun into the booth press the gun trigger and visu ally check the powder output Note As a factory default value a powder rate of 60 and a total air vol ume of 4 Nm h are recommended By inserting values which the equipment cannot convert the operator is made aware by flashing of the appropriate display and a temporary out of range message Setting the electrode rinsing air 1 Adjust the correct electrode rinsing air according to the ap plied nozzles deflector plate flat jet nozzle see note below for default starting values Press key T9 SELECT The second display level is switched over Press keys T7 T8 Here the corresponding air volume value is entered If this display level is not operated for 3 seconds the first display level is switched over independently OptiFlex B manual coating equipment m iTw Gema Note By using flat jet nozzles the factory default value is approx 0 2 1 Nm h by using round jet nozzles with air rinsed deflector plates the factory default value is approx 0 5 Nm h Setting the fluidizing The fluidizing can be adjusted on the OptiFlex B OptiFlex S and OptiFlex F Manual coating equipment The powder fluidizing depends on the powder type the air humidity and the ambient temperature Fluidizing and vibration start by switching o
28. manual coating equipment iTw Gema Switch on the booth Switch on the powder coating booth according to its operating manual Daily start up The daily start up of the OptiStar CG07 Manual gun control unit takes place by the following steps Select the operating mode Select the application mode with three predefined modes Preset mode or the user defined program mode with 20 user defined programs Pro gram mode 1 Turn on the gun control unit with the ON key 2 Select the corresponding application mode vvith key T12 for CP Program mode or keys T13 T14 T15 for Preset mode The predefined mode automatically set values for high voltage and spray ing current Presetting Desired pA Desired kV Flat parts 100 100 Predefined application mode Preset mode lt 3 Select the preset mode with the application keys T13 T14 T15 The LED 4 of the corresponding key illuminates No program number will be shown on the display A5 The air values can be individually specified and are automatically stored in the corresponding program Application mode for flat parts This application mode is suitable for the coating of simple flat workpieces without larger cavities Application mode for complicated parts This application mode is suitable for the coating of three dimensional workpieces with complicated shapes e g profiles Application mode for recoating parts already coated This application mode is suitable for rec
29. n the control unit Procedure 1 Adjust the air mover by turning the ball valve fully open and adjusting needle valve as required The ball valve and needle valve are located on the air mover OptiFlex F 2 Open the powder hopper cover 3 Press key T9 SELECT SELECT The second display level is switched over 4 Adjust the fluidizing air with the keys T5 T6 If the adjustment keys or are not operated after 3 seconds the display will go back to the HA display The povvder should simmer inside the hopper Occa sional mixing of the povvder might be required Close the cover again According to the device type stirrer vibration and or fluidiz ing can be switched on now Powder coating Attention Make sure first that all electrically conductive parts within 5 m of the coating booth are grounded 1 Take the gun into the hand and hold it into the coating booth but do not yet direct it to the object to be coated 2 Select the operating mode O Select the operating mode with program key T12 or applica tion keys T13 T14 T15 The LED of the corresponding appli cation key illuminates 3 Adjust powder delivery and total air settings as required This will need to be done as the gun is triggered to visualize the spray pattern 4 Press the powder gun trigger 5 Coat the objects OptiFlex B manual coating equipment Start up and operation 27 iTw Gema Remote control by GM02 manual gun
30. n or not inserted Replace or fit the insert nozzle 64 Troubleshooting guide OptiFlex B manual coating equipment T iTw Gema Spare parts list OptiFlow 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 OptiFlex K 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 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 N explosion protection vvill also be preserved that vvay The use of spare parts from other manufacturers vvill invalidate the ITVV Gema guarantee conditions OptiFlex B manual coating equipment Spare parts list OptiFlow 65 iTw Gema OptiFlovv powder injector 1502 type spare parts list OptiFlow powder injector complete pos 1 9 391 530 1 Injector body without pos 2 1000 132 2 O ring 16x2 mm 231 5178 3 Insert sleeve PTFE 377 7248 4 con
31. nection complete incl pos 4 1 387 827 4 1 O ring 15x1 mm 266 930 5 Threaded sleeve 387 819 6 Check valve conveying air red marking complete incl pos 8 and 9 261 211 f Check valve supplementary air black marking complete incl pos 8 and 9 261 203 8 Ball 240 168 9 Spring 240 176 14 Quick release coupling red for conveying air hose 8 6 mm 261 645 15 Quick release coupling for supplementary air hose 8 6 mm 261 637 16 Conveying air hose 8 6 mm red 103 500 17 Supplementary air hose 2 8 6 mm black 103 756 18 Quick release coupling for hose 2 8 6 mm 203 181 Powder hose type 1001 PUR 2 16 11 mm standard for automatic guns 103 012 Powder hose type 1004 PVC 16 11 mm standard for manual equipment 103 128 Powder hose type 1005 PVC 20 12 mm for manual equipment 100 080 Powder hose type 66 POE 2 16 11 mm with conductive strip for automatic 105 139 guns Powder hose type 74 POE 2 15 10 mm with conductive strip for automatic 1001 673 guns hose type 75 POE 18 12 mm with conductive strip for automatic 1001 674 guns Wearing part Please indicate length 66 e Spare parts list OptiFlow OptiFlex B manual coating equipment m iTw Gema OptiFlow powder injector IG02 type spare parts Automatic equipment Manual equipment rcm OptiFlow powder injector 1602 type spare parts OptiFlex B manual coating equipm
32. oating of workpieces which are already coated Exiting the Preset mode Exit the Preset mode with the keys T10 T11 or T12 The preset values of E T p the Program mode used before the Preset mode are displayed by the control unit memory OptiFlex B manual coating equipment Start up and operation e 25 iT Gema SELECT 26 e Start up and operation V 05 10 User defined mode Program mode Select this application mode with the key T12 Here 20 user defined pro grams can be set and saved The programs 1 20 were loaded with pre sets by factory 4 0 Nm h total air 6096 powder output 80 kV high volt age 80 pA spray current 0 2 Nm h electrode rinsing air and 1 0 Nm h fluidizing air Setting powder output and powder cloud The powder output is dependent on the selected powder amount in 96 and the adjusted total air volume Setting the total air volume 1 Adjust the total air volume with the keys T3 T4 see also the injector operating manual Adjust the total air volume according to the correspond ing coating requests Setting the powder output 1 Adjust the powder output volume e g according to the de sired coating thickness The selection takes place with the keys T1 T2 on the control unit or with the keys on the rear side of the powder gun OptiSelect gun type Factory default setting of 6096 is recommended for initial spraying The total air volume is thereby kept constant automatical
33. omplete positive polarity incl gun cable 6 m rinsing air hose 6 m flat jet nozzle brush 1002 101 and parts kit without powder hose B OptiSelect manual powder gun shaft incl cascade Negative polarity 1001 891 Positive polarity 1001 892 C Cascade negative polarity complete 1000 809 Cascade positive polarity complete 1002 031 1 Gun body 1001 155 Handle complete set pos 5 6 7 and 8 1000 807 2 Trigger complete incl pos 2 and 3 1001 341 3 Compression spring 0 36x4 2x49 4 mm 1001 487 4 Trigger cover 1000 801 5 Grasp termination 1000 806 6 Radial gasket 1000 803 7 Gun cable L 6 m complete 1001 528 Extension cable for gun cable L 26m incl safety clamp 1002 161 Extension cable for gun cable L 214m incl safety clamp 1002 162 Safety clamp for extension cable 1002 064 8 Grub screw M3x8 mm 1000 844 10 Powder tube complete 1001 339 10 2 O ring 12x1 5 mm 1000 822 11 Rinsing air connection 1000 804 12 Clip ring 1000 898 13 Compression spring 1001 488 OptiFlex B manual coating equipment Spare parts list OptiSelect e 49 iTw Gema OptiSelect Manual powder gun spare parts list OptiSelect Manual powder gun spare parts 50 e Spare parts list OptiSelect OptiFlex B manual coating equipment V 05 10 iT Gema OptiSelect Manual powder gun spare parts list cont
34. ricity These general safety regulations must be read and understood mandatory be fore start up OptiFlex B manual coating equipment General safety regulations 7 OptiFlex B Scope of delivery T iT Gema OptiFlex B manual coating equipment structure OptiFlex B manual coating equipment A OptiStar control unit 1 in a metal case with power supply cable A mobile trolley with a gun hose support 4 A vibrating base 6 and a fluidizing suction unit 5 A plug in OptiFlow Injector 3 An OptiSelect manual powder gun 2 with gun cable powder hose rinsing air 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 Spare parts set OptiFlex B 9 iTyvGema vin Technical data OptiFlex B manual coating equipment Electrical data OptiFlex B manual coating equipment 080 s 230 240 VAC Nominal input voltage 110 120 VAC Input value 150 VA Pneumatical data OptiFlex B manual coating equipment Max compressed air consumption 8 m h Dimensions OptiFlex B manual coating equipment KG oo Height 1135 mm Weight 58 kg 10 Technical data OptiFlex B manual coating equipment Start up T iTw Gema Check the compressed air connection from the filter unit to the control unit Connect the compressed air supply hose from the compressed air circuit direc
35. rnings 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 ATTENTION Improper use of the equipment could damage the machine or cause it to malfunction Possible consequences Minor injuries or damage to equip ment NOTE Useful tips and other information OptiFlex B manual coating equipment General safety regulations 3 iTw Gema The OptiFlex manual coating equipment is built to the latest specification and conforms to the recognized technical safety regulations and it is de signed for the normal application of powder coating 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 If the OptiFlex manual coating equipment is to be used for other purposes or other substances outside of our guidelines then General ITW Gema GmbH should be consulted information Observance of the operating service and maintenance instructions specified by the manufacturer is also part of conformity of use The relevant accident prevention regulations as well as other generally recognized safety regulations occupational health and structural regula tions are to be observed Furthermore the count
36. rol unit and to the injector this hose is electrically conducting Connect the mains cable to the 2 1 Power IN plug and tigh ten with provided screw If no vibration motor OptiFlex B is connected the 2 2 Aux output is to be locked tightly with the provided protection cap OptiFlex B manual coating equipment Povver IN V 05 10 iT Gema Filter unit Fluidizing air L Connecting guide overview Pin assignment Power IN connection 1 Neutral conductor power supply 2 Phase conductor 100 240 VAC 3 Stirrer output PE Ground PE Aux connection Vibrator phase output Neutral conductor 3 Not used PE Ground PE Gun connection Ground Remote control 1 GMO2 Chassis ground Trigger Remote control 2 GMO2 Oscillator PE Ground PE O O G N OptiFlex B manual coating equipment IL n L I m 5 E Start up and operation 23 iT Gema Initial start up 24 e Start up and operation V 05 10 Setting the device type Adjust the corresponding device type fluidizing box or stirrer device by pressing the key T16 Note If the control unit is supplied as a component of an OptiFlex com plete unit then the corresponding system parameter is set correctly by the factory Manual devices are subdivided into fluidizing box or stirrer types These types differ in the control of the vibrator output and the
37. rrectly stored in EEPROM error EEPROM during switching off Throttle motors Throttle motor or needle blo Calibrate again replace throttle Conveying air reference position cked limit switch defective valve not found throttle motor error unla RR Throttle motor or needle blo see above A ry P cked limit switch defective sition not found throttle motor error n Throttle motor or needle blo see above Electrode rinsing air reference aie l cked limit svvitch defective position not found throttle motor error ud Ra EE Throttle motor or needle blo see above ping al g cked limit switch defective ence position not found throttle motor error Conveying air throttle does not Short circuit in limit switch throt see above move tle motor defective Supplementary air throttle does Short circuit in limit switch throt see above not move tle motor defective Electrode rinsing air throttle Short circuit in limit switch throt see above does not move tle motor defective Shaping air fluidizing air throttle Short circuit in limit switch throt see above does not move tle motor defective Convevngarnosiioniost Lost steps limit switch defective see above throttle motor defective Lost steps limit svvitch defective see above PP throttle motor defective ElncrodEtinsinimaliost Tes Lost steps limit switch defective see above g alr p throttle motor defec
38. ry specific safety regulations also must be ob served Further safety and operation notices will be found on the accompanying CD or on the homepage www itwgema ch The start up is forbidden until it has been established that the manual co ating equipment has been set up and wired according to the EU guide lines for machinery Unauthorized modifications to the manual coating equipment exempts the manufacturer from any liability from resulting damages or accidents The operator must ensure that all users do have the appropriate training for powder spraying equipment and are aware of the possible sources of General danger danger Any operating method which will negatively influence the technical safety of the powder spraying equipment is to be avoided 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 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 the ITW Gema GmbH guarantee would no longer be valid These general safety regulations must be read and understood mandatory be fore start up 4 General safety regulations OptiFlex B manual coating equipment m iTw Gema The connecting cables between the control unit and the spray gun m
39. select a larger powder hose inside diameter 12 mm i d Note It Should be considered that by irregular or pumping conveying normally the total air is set too low General conditions for the OptiFlow injector Powder type Epoxy Polyester OptiFlex B manual coating equipment m iTw Gema Guide values for OptiStar OptiTronic with OptiFlow injector All values in these tables are guide values Differing environmental condi tions wear and different powder types can change the table values Total air 4 Nm h 5 Nm h 6 N h Powder output g min ER ES Powder output AB GO l mi 0 0 75 9 110 OptiStar OptiTronic 110 45 150 215 20 J 235 20 0 20 30 40 150 s0 130 160 45 60 80 90 100 OptiFlex B manual coating equipment e 61 iTw Gema mes Cleaning and maintenance Injector cleaning Cleaning should be done daily before starting work or at color change 1 Remove the injector from the hopper 2 Pull powder hose off the hose fitting 4 3 Clean the hose fitting 4 with compressed air which is free of water and oil and check for wear 4 Clean injector body 1 with compressed air which is free of water and oil Any contamination can be seen through the opening of the powder hopper fitting 2 5 Reassemble the injector and fit it on the hopper Attention If the injector is severely contaminated it m
40. t OptiFlex B OptiFlex B manual coating equipment V 05 10 OptiFlex B fluidizing suction unit iT Gema 1 Bearing bush 1002 046 2 Guide sleeve 1002 052 3 Locknut M48x1 5 mm plastic 1002 051 4 Fluidizing suction unit 40x534 mm complete incl pos 5 9 362 425 o Adapter nipple 1 8 i 1 8 a 200 930 6 Bezel 0 3 mm 338 303 7 Elbow 1 8 a 1 8 a 235 733 8 Plug NW5 1 8 i 200 859 9 Fluidizing pad 1 8 a 237 264 10 Cable sleeve 2 4 8 1 5 mm 265 276 11 Retaining bracket 1002 054 A Pneumatic connection fluidizing air complete incl pos 12 13 and 14 1002 041 12 Quick release connection NW5 6 mm 200 840 13 Nut with kink protection M10x1 mm 6 mm 201 308 14 Plastic hose 6 4 mm black 1001 973 15 Swivel arm incl pos 10 1002 045 OptiFlex B manual coating equipment OptiFlex B fluidizing suction unit Spare parts list OptiFlex B 17 iTw Gema we OptiFlex B 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 0 10 mm 239 267 OptiFlex B fil
41. ter unit 18 Spare parts list OptiFlex B OptiFlex B manual coating equipment T iTw Gema OptiStar CG07 Operating modes The OptiStar CG07 Manual gun control unit can be operated with two operating modes According to the selected application mode the spray voltage and the spray current are automatically adjusted and limited Predefined operating mode Preset mode The CG07 Manual gun control unit provides three predefined application modes flat parts complicated parts and recoat parts already painted one time When operating in this mode the spray voltage and spray current are automatically set and limited In this operating mode current HA and high voltage kV are preset powder and air volume can be adjusted and saved The powder and air volume are stored separately for each predefined application mode User defined operating mode Program mode In this operating mode 20 individually definable programs P01 P20 are available These programs are automatically saved and can be recalled again as the application requires The values for current high voltage powder output total air electrode rinsing air and fluidizing air if available can be set as needed for a given application Note e The specified values in the 20 programs and 3 application modes 1 are saved automatically without confirmation after a two second delay and the display changes from preset values to actual values OptiFlex B manual co
42. th or the suspen sion device 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 conveying air to the corresponding output 1 2 on the rear side of the control unit and to the injec tor Connect the black hose for supplementary air to the corre sponding 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 plug 2 1 Power IN and screw it on Start up and operation 41 iTyvGema Filter unit Fluidizing air Injector L X Connecting guide overview Function check 1 Turn on the gun control unit 2 Press the desired application key Preset or Program Mode on the control unit see gun control unit operating instruc tions 3 Pickthe gun up and point it at a grounded object at a dis tance of approx 20 cm 4 Press the powder gun trigger The display for current and high voltage on the control unit shows the actual value The high voltage is present in the OptiSelect gun and the LED illuminates The high voltage can be set with the corresponding keys See also the control unit operating instructions 5 Select the powder output and total air
43. tic manual powder coating equipment The grounding cable must have a good metallic connection with the coat ing booth the recovery unit and the conveyor chain respectively with the suspension arrangement of the objects Smoking and igniting fire are forbidden in the entire plant area All spark generating works are forbidden As a general rule for all powder spraying installations persons with pa cemakers should never enter high voltage areas or areas with electro magnetic fields Persons with pacemakers should not enter areas with powder spraying installations The stay for persons with cardiac pacemakers is forbidden 6 General safety regulations OptiFlex B manual coating equipment me iTw Gema 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 should only be removed when the power supply is switched off Disconnect from mains before maintenance works take place As far as it is necessary the operating firm must ensure that the operat ing personnel wear protective clothing e g facemasks The operating personnel must wear electrically conductive footwear e g leather soles The operating personnel should hold the gun with bare hands If gloves are worn these must also conduct elect
44. tive Shaping air fluidizing air posi Lost steps limit switch defective see above tion lost throttle motor defective H67 H70 71 H 30 e Start up and operation OptiFlex B manual coating equipment iTyvGema Help codes list The last appeared four errors are stored in a list by the software If an er ror appears which is already in the list it will not be listed again If the list is full no more new entries are added Appearance of errors It is possible that an error appears just shortly but after the acknowl edgement it will disappear In this case switch off the OptiStar control unit and switch it on again Reset by restarting OptiFlex B manual coating equipment Start up and operation e 31 iTw Gema mes Spare parts list OptiStar 07 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 OptiFlex C Manual coating equipment Serial number 1234 5678 Order no 203 386 1 piece Clamp 2 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
45. tly to the filter unit main connection on the rear side of the equipment 1 4 female BSP Note 1 Ine compresse am a n ANd WAE 2 OptiFlex B manual coating equipment Connect the black hose for fluidizing air 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 conveying air to the corresponding output 1 2 on the rear side of the control unit and to the injec tor Connect the black hose for supplementary air to the corre sponding output 1 3 on the rear side of the control unit and to the injector this hose is electrically conducting Connect the mains cable to the 2 1 Power IN plug and tigh ten with provided screw Start up 11 iTw Gema S s LD Fluidizing air Injector S Connecting guide overview Note e The further start up procedure for the OptiFlex B manual coating 1 equipment gun is explicitly described in the OptiStar CG07con
46. trol unit operating instructions chapter Initial start up and Daily start up 12 e Start up OptiFlex B manual coating equipment Va iTyvGema Maintenance and cleaning e Note i A regular and conscientious maintenance increases the operating life of the unit and ensures a longer constant coating quality Daily maintenance 1 Clean the injector see the OptiFlow user manual 2 Clean the powder gun see the OptiSelect user manual 3 Clean the powder hose Weekly maintenance 1 Clean fluidizing suction unit injector and powder gun Just place the fluidizing suction unit in 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 con veyor chain If in disuse for several days 1 Disconnect 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 B manual coating equipment Maintenance and cleaning e 13 iTw Gema mes Spare parts list OptiFlex B Ordering spare parts When ordering spare parts for powder coating equipment please ind
47. ust be installed in such a way that they cannot be damaged during the op eration Please observe the local safety regulations 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 Electrical danger The powder coating equipment may be able to be switched on only if the booth is in operation If the booth stops the powder coating device must switch off too i b 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 spare parts will guarantee that the explosion protection will be preserved If damages occur by using spare parts from other manufacturers the warranty or compensation claim is void Conditions leading to dangerous levels of dust concentration in the pow der 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 max permissible powder air concentration If the UEG is not known then a value of 10 g m should be considered see EN 50177 Explosion hazard All unauthorized conversions and modifications to the electrostatic spray ing equipment are forbidden for safety reasons No safety devices should be dism
48. ust be dismantled Re move the check valves 6 and 7 with the correct sized spanner Clean the parts with compressed air and if necessary dissolve sin tered deposits with nitro thinners Don t use acetone don t scrape 1 Injector body 6 Check valve conveying air 2 Powder hopper connection 7 Check valve supplementary air 4 Powder hose connection 62 e Cleaning and maintenance OptiFlex B manual coating equipment Tema Cleaning the check valves Note Take care by dismantling the check valve because the ball spring can easily be lost 1 Check valve 2 Ball 3 Spring Note 1 Do not immerse the ball in solvent The OptiFlow injector should be cleaned once daily as a minimum Nor mally it is sufficient to clean as described on the previous page The injector should be dismantled completely once a week or in the case of heavy contamination see also the figure in the spare parts list OptiFlex B manual coating equipment Cleaning and maintenance e 63 iTw Gema mes Troubleshooting guide Problem fixing The injector could be dirty or clogged if the powder gun does not spray powder in spite of the control unit being switched on Error cause Repair Injector nozzle check valve powder Clean corresponding part if nec hose or powder gun are clogged essary replace Too little conveying vacuum Increase the powder volume and or total air volume on the control unit Insert sleeve wor
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