OptiFlex S manual coating equipment - spare parts
Contents
1. ponding enclosed documentation OptiFlow injector All information about the OptiFlow injector will be found in the corres ponding enclosed documentation OptiFlex S manual coating equipment iTw Gema Stirrer recipient The powder in the stirrer recipient is agitated and kept loose by the stirrer arm The injector sucks in the powder by means of the conveying air 1 The powder air mixture attains to the gun through the powder hose 2 and is electrostatically charged in the gun nozzle In addition an electros tatic field is created between the gun nozzle and the grounded object The electrostatically charged powder sprayed onto the workpiece ad heres on the surface of the grounded object Because of the conical shape of the stirrer recipient the powder can be used completely opti mum powder consumption Conveying air supplementary air and rinsing air are set on the OptiStar control unit see therefore the corresponding user manual The function of the used injector is described in the corresponding user manual Stirrer recipient function OptiFlex S manual coating equipment Function description e 15 TvyGema Scope of delivery V 05 10 OptiFlex 1 S A OptiStar control unit in a metal case with power supply cable A mobile trolley with a gun hose support A powder recipient with stirrer and cover inclusive mains adaptor for the stirrer A plug in OptiFlow injector An OptiSelect manual powder g2. Fault elimination General information Fault Causes Fault elimination Power pack defective Replace the power pack 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 cap 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 LED remains dark although the gun trigger is operated Gun plug gun cable or gun cable connection defective Gun plug gun cable or gun cable connection defective Remote control on powder gun defective Replace corresponding part or send in for repair Replace corresponding part or send in for repair Replace remote control gun cap Powder does not ad here to object al though the gun trigger is operated and the gun sprays powder High voltage and cur rent 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 S manual coating equipment Fault elimination e 27 iTw Gema 28 e Fault elimination V 05 10 Fault Causes Fault elimination Control unit displays r
3. M5x12 mm 257 052 22 Injector OptiFlow IG02 V complete see corresponding user manual 34 e Spare parts list Wearing part Please indicate length OptiFlex S manual coating equipment iri Gema OptiFlex S stirrer recipient OptiFlex S stirrer recipient OptiFlex S manual coating equipment Spare parts list e 35 iTw Gema vos OptiFlex S stirrer drive unit Stirrer drive unit complete pos 1 13 393 940 1 Stirrer motor with gear unit and stirrer case 393 932 2 Stirrer motor with pinion 268 950 Stirrer motor 269 255 Drive belt 268 941 Electronic board for stirrer control complete incl pos 5 388 173 Stirrer control power supply 389 277 5 Mains push button complete with cable 390 542 Cable set consisting of 6 Power pack connecting cable 390 550 7 Connecting cable 24 VDC 390 569 8 Grounding wire 391 867 9 Fixture set for power pack board consisting of two pieces each Standoff M3 SW5 5x12 mm 267 775 Standoff M3 SW5 5x10 mm 267 007 Cylinder screw 245 821 Shake proof washer 205 885 10 Fuse 2 AT 221 872 11 Adaptor cable for stirrer connection 391 905 12 Gland 265 780 13 Gasket for stirrer motor 393 924 36 e Spare parts list OptiFlex S manual coating equipment iTw Gema OptiFlex S stirrer drive unit OptiFlex S stirrer drive unit OptiFlex S manual coating equipment Spare parts list e 37 iTrv Gema T O
4. 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 AII electricity conducting parts and machinery found in the workplace ac cording to DIN VDE 0745 part 102 must be
5. compressed air consumption 7 mh Connectable guns OptiFlex S manual coating equipment connectable OptiSelect GM02 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 OptiFlex S manual coating equipment Technical Data e 17 ITWwGema AN 18 e Technical Data V 05 0 Attention The OptiFlex S manual coating equipment may be used only with the specified gun types Dimensions OptiFlex S manual coating equipment Width 691 mm Depth 764 mm Height 1135 mm Weight 58 kg OptiFlex S manual coating equipment iTw Gema Start up and operation Connecting guide Note 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 The compressed air must be free from oil and water 2 Note 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
6. minor injuries or damage to equip ment e INFORMATION 1 Useful tips and other information Conformity of use 1 The OptiFlex S 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 S manual coating equipment is to be used for other purposes or other substances outside of our guidelines then ITW Gema GmbH should be consulted 3 Observance of the operating service and maintenance instruc tions specified by the manufacturer is also part of conformity of OptiFlex S manual coating equipment General safety regulations e 3 iTrv Gema V 05 10 use The OptiFlex S 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 S 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 S manual coating equip ment exempts the manufacturer from any liability
7. powder gun controls powder guns etc should be referenced to their corresponding documents OptiFlex S manual coating equipment About this manual e 11 heat iTw Gema Function description Field of application The OptiFlex S manual coating equipment with stirrer recipient is built exclusively for electrostatic coating with organic powders Any other use of the product will be considered as non intended use The manufacturer is not responsible for any damage resulting from this the risk is assumed by the user alone The OptiFlex S electrostatic powder manual coating equipment with the OptiSelect manual powder gun is ideally suited for manual coating of ob jects in larger series Typical characteristics Processing the powder from the stirrer recipient Quick and simple color change Supplied ready for use Available with one or two guns extensible OptiFlex S manual coating equipment Function description e 13 irv Gema V 05 10 OptiFlex S manual coating equipment Structure 14 e Function description OptiFlex S manual coating equipment structure 1 OptiStar control unit 8 2 OptiSelect manual powder gun 9 3 OptiFlow injector 10 4 Mobile frame with hand rail 11 5 Stirrer recipient 12 6 Swivel wheel 13 7 Filter unit OptiStar control unit Hose holder Hose connections Discharge flap Filler flap Shelf Rubber wheel All information about the OptiStar control unit will be found in the corres
8. the powder hose again to the hose connection on the injector OptiFlex S manual coating equipment Maintenance and cleaning e 25 iTw Gema T Cleaning Cleaning the OptiSelect manual powder gun Frequent cleaning of the gun helps to guarantee the coating quality 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 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 1 See therefore the user manual of the OptiSelect manual powder gun Maintenance and cleaning of the filter unit The filter unit on the OptiFlex 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 Unscrew the filter glass on the filter unit Loose the cap screw Remove the complete filter element Replace the filter element ov dm o m Clean the filter glass on the inside and install it again 26 e Maintenance and cleaning OptiFlex S manual coating equipment iTw Gema V 05 10
9. Insert sleeve PTFE 377 724 Injector plug gauge 393 380 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 23 Shortinstruction sheet OptiStar CG07 1002 060 24 Program table sheet OptiStar CG07 1002 063 32 e Spare parts list Please indicate length OptiFlex S manual coating equipment iTw Gema OptiFlex S manual coating equipment spare parts OptiFlex S manual coating equipment spare parts OptiFlex S manual coating equipment Spare parts list e 33 ITwWGema vani OptiFlex S stirrer recipient 1 Mini stirrer brush 366 862 2 Main filler cover 1001 730 3 Filler flap 1001 731 4 Hinge 305 472 5 Powder container 366 854 6 Gasket for powder container 101 630 7 Cardan joint 12 mm H7 206 369 8 Protective cover for cardan joint 206 350 9 Manifold 379 395 10 O ring 67 2 mm 236 403 11 Gasket for discharge flap 303 240 12 Discharge flap with toggle clamp incl pos 11 303 194 13 Blind grommet complete incl pos 14 380 296 14 O rring for blind grommet 231 517 15 Injector retainer 380 288 16 Wedge for cardan joint 4x4x12 mm round 269 263 17 Grub screw for cardan joint M4x4x16 mm round 206 075 18 Grub screw for cardan joint hexagon spiky 214 728 19 Countersunk Allen screw M3x10 mm 248 444 20 Shakeproof Allen screw M6x16 mm 261 823 21 Shakeproof Allen screw
10. Operating instructions and spare parts list OptiFlex Manual coating equipment Cc o E Translation of the original operating instructions ITwGema V 05 10 Documentation OptiFlex S manual coating equipment Copyright 2006 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 con
11. 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 S manual coating equipment Color change e 23 iTw Gema Maintenance and cleaning Note o 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 Cleanthe injector 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 stirrer recipient the injector and the 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 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
12. agrams 29 Block diagram OptiFlex S sess enne nns 29 Pneumatic diagram OptiFlex S enne 30 Spare parts list 31 Ordering spare parts nter cete Petite alana 31 OptiFlex S manual coating equipment spare parts list eenen 32 OptiFlex S manual coating equipment spare parts ii 33 OptiFlex S stirrer recipient ii 34 OptiFlex S stirrer recipient iii 35 OptiFlex S stirrer drive UNIt ii 36 OptiFlex S stirrer drive UNIt ii 37 OptiFlex S filter Unit 2 iai iier eet td E E EHE Ht pete arat 38 2 e Table of contents OptiFlex S manual coating equipment 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 S manual coating equipment These safety regulations must be read and understood before the OptiF lex S 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 equipment could damage the machine or cause it to malfunction Possible consequences
13. 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 corres ponding 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 If no stirrer is connected the 2 2 Aux output is to be locked tightly with the provided protection cap OptiFlex S manual coating equipment Start up and operation e 19 iTrv Gema T e El QO Filter unit e Fluidizing air Em Injector Ho Connecting guide overview Preparation for start up Fill the stirrer recipient with powder 1 Open the hinged flap of the stirrer recipient cover 2 Fill in the coating powder in the stirrer recipient Maximum filling level of the powder is marked on the inside of the recipient use ful capacity approx 18 5 dm3 Close the hinged flap of the stirrer recipient cover The stirrer can be put into operati
14. ample 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 invalidate the ITW Gema guarantee conditions OptiFlex S manual coating equipment Spare parts list e 31 iTw Gema vaso OptiFlex S manual coating equipment spare parts list 1 Bearing bolt 1000 453 2 Hexagon shakeproof nut M6 244 430 3 Countersunk Allen screw M6x30 mm 1002 952 4 Handle bar 1002 623 5 Counter washer 1000 944 6 Rubber wheel 200 mm 260 592 7 Swivel wheel 50 mm 260 606 8 Grounding cable complete 301 140 9 Countersunk Allen screw M6x20 mm 1002 992 10 Clamp 1003 077 11 Countersunk Allen screw M6x40 mm 1002 953 12 Gun retainer 1003 076 13 CG07 gun control unit complete not shown see corresponding user manual 14 Plastic hose 8 6 mm black 103 756 15 Hose holder 1000 699 16 Filter unit complete see corresponding spare parts list 17 Stirrer recipient see corresponding spare parts list 18 Ribbed cylinder Allen screw M10x20 mm 260 584 19 Snap ring A 25 237 094 20 Hexagon ribbed cylinder screw M8x16 mm 261 793 21 OptiFlow IGO2 V injector complete see corresponding user manual 22 Spare parts set MS03 consisting of 1002 016
15. earthed 1 5 meters either OptiFlex S manual coating equipment var 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 additional measures such as barriers to prevent unau thorized access Prohibiti
16. ecautions 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 S manual coating equipment 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 If ITW 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 electromagnetic fields Persons with pacemakers should not enter areas with po
17. elevating aaa 15 Scope of delivery sorses m uidere i aaa 16 OptirleX1 Si DERE 16 Additional supply for OptiFlex 2 S iii 16 Technical Data 17 OptiFlex S manual coating equipment 17 Electrical Data bete eo HIE ON Od 17 PneumatiCal Data ire eain oido eee 17 Connectable guns ene enne entente nnne tenens 17 DIMENSIONS ect neget ER gd 18 Start up and operation 19 Connecting guide i 19 Preparation for Start Up ennen ere nerne ener enne nennen 20 Fill the stirrer recipient with powder enn ke nn kernen knnnee 20 Switching on the booth ii 20 Stalt Upr ti eno 20 UL ES cede AA EATA EA T n Ie IEEE 20 Switch on the control UNIt ii 21 OptiFlex S manual coating equipment Table of contents e 1 ITwGema V 05 10 Color change 23 General information nori ea til eer lth ti her atta dete 23 Maintenance and cleaning 25 Daily maintenance i 25 Weekly maintenanc oiu ENE Dia a 25 If in disuse for several days enne 25 Powder hose rlhslng filo caio riali la ati cen nan 100 25 Cleaning artefatto alia E lago lalla une 26 Cleaning the OptiSelect manual powder gun i 26 Maintenance and cleaning of the filter unit esses 26 Replacing the filter element nssr nnnnnnrrnnnnenn nennen 26 Fault elimination 27 General information ais ocio ere calci 27 Schematic di
18. emain 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 flui dized The gun does not spray powder al though the control unit is switched on and the gun trigger is operated Compressed air not present Fluidizing air is set too low on the control unit Motor throttle defective Compressed air not present Injector motor throttle 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 Motor throttle defective Solenoid valve defective Front plate defective Connect the equipment to the compressed air Set the fluidizing air cor rectly Replace the motor throt tle Connect the equipment to the compressed air Clean corresponding part Replace Insert the insert sleeve see above Replace the motor throt tle Replace the solenoid valve Send in for repair OptiFlex S manual coating equipment heat iTw Gema Schematic diagrams Block diagram OptiFlex S perte ei 4 OptiStar CG07 i Foil Keypad Mainboard i Powe AK J Block diagram OptiFlex S OptiFlex S manual coating equi
19. 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 not T4 zone 22 Technical safety regulations for stationary electrostat ic powder spraying equipment 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 4 e General safety regulations 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 regulations DIN VDE 0147 Part 1 must be observed for safe operation Safety pr
20. hing 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 7 The electricity and powder supply to the hand guns must be set up so that they are fully protected against heat and chemical damage 8 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 9 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 10 The control device must be switched off if the hand gun is cleaned or the nozzle is changed 11 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 12 The manufacturers instructions and the applicable environmental requirements must be observed when disposing of powder lac quer and cleaning agents 13 If any part of the spray gun is damaged broken parts tears or missing then it should not be used 14 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 should be used 15 Repairs must only be carried out by specialists and under no cir cumstances sh
21. hod which will negatively influence the tech nical safety of the powder spraying equipment is to be avoided OptiFlex S 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 it is necessary the operating firm must ensure that the operating personnel wear protective clothing e g facemasks 7 The operating firm must guarantee cleanliness and an overview of the workplace with suitable instructions and
22. ic spraying equipment 4 DIN VDE 0165 Setting up electrical equipment in locations in areas with danger of explosion OptiFlex S manual coating equipment General safety regulations e 9 iTw Gema yest Sources Carl Heymanns Verlag KG Luxemburger Strasse 449 5000 K ln 41 or from the appropriate employers association 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 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 General safety regulations OptiFlex S manual coating equipment FESTE iTw Gema About this manual General information This operating manual contains all important information which you re quire for the working with the OptiFlex S manual coating equipment It will safely guide you through the start up process and give you references and tips for the optimal use of your new powder coating system Information about the function mode of the individual system components reciprocators booths
23. on by pressing manually the button on the cover when filling emptying Switching on the booth The coating booth is switched on according to the corresponding user manual Start up Stirrer The stirrer starts by pressing the gun trigger By letting loose the gun trigger the stirrer runs after for approx 15 20 seconds So open the cov er only after the stirrer has stopped By raising the stirrer cover the en gine switches off 20 e Start up and operation OptiFlex S manual coating equipment iTw Gema Switch on the control unit 1 Press the ON power switch The displays illuminate and the control unit is ready for operation Note Oo The further start up procedure for the OptiFlex S manual coating 1 equipment gun is explicitly described in the OptiStar CGO7control unit operating instructions chapter Initial start up and Daily start up OptiFlex S manual coating equipment Start up and operation e 21 FESTE 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 stirrer recipient 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 Fit the powder hose
24. on 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 of the 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 S manual coating equipment General safety regulations e 7 iTw Gema T 6 The supplied earthing cable green yellow must be connected to the earthing screw of the electrostatic powder spraying hand ap pliance The eart
25. ould they be carried out in the operating area The former protection must not be reduced 16 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 8 e General safety regulations OptiFlex S manual coating equipment V 05 10 iTw Gema 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 VDMA 24371 Guidelines for electrostatic coating with synthetic powd er Part 1 General requirements Part 2 Examples of use Leaflets ZH 1 310 Leaflet for the use of tools in locations where there is danger of explosion 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 poten
26. pment Schematic diagrams e 29 iTrv Gema oe Pneumatic diagram OptiFlex S Supplementary air OptiStar CG07 I I fi z Conveying air I I E1 i i T I j i 12v 7 I T i Ji i I i I I Cm Um Com FL oM i LI LI LI LI la NI kd I fa ku 4 I i ll j Fog 5 LUI N Ds il j hi L II Id LUI LI AT I II Rd LUI I 3 SE ef he Se ech dardo ul cioe 11 5 14 13 12 Adjust to 5 5 bar by 6 Nm h air con sumption Bc M1 z Motor throttle E1 z Input unit Electrode rinsing air 3 10 l min Pneumatic diagram OptiFlex S 30 e Schematic diagrams OptiFlex S manual coating equipment 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 OptiFlex S 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 Ex
27. ptiFlex S 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 10 mm 239 267 1 gt 2 J ey CS D OptiFlex S filter unit 38 e Spare parts list OptiFlex S manual coating equipment rei iTw Gema OptiFlex S manual coating equipment Spare parts list e 39
28. tents 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 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 T iTw Gema Table of contents General safety regulations 3 Safety symbols pictogramSs eene nnns 3 Conformity Of US ii 3 Technical safety regulations for stationary electrostatic powder spraying equipment iran io i n reni oe 4 General information sse nennen 4 Safety conscious working sse 5 Individual safety regulations for the operating firm and or operating personnel cieli eil 5 Notes on special types of hazard i 6 Safety requirements for electrostatic powder coating 7 A summary of the rules and regulations ii 8 Product specific security measures sss 10 About this manual 11 General informatlohi 5 10 ert d etd t E He E edis 11 Function description 13 Field of application i 13 Typical characteristiCS i 13 OptiFlex S manual coating equipment 14 Sine ES 14 OptiStar control unit essent 14 OptiFlow injector sese enne nennen nnne 14 Stirrer reclpleli uitio etuer reote tpe ceti
29. tially explosive atmospheres EN 292 1 EN 292 2 Machine safety 2 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 3 EN 50 177 Stationary electrostatic spraying equipment for flamma ble coating powder 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 2 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 General regulations Supplementary definitions for stationary electrical spray ing equipment DIN VDE 0147 part 1 Setting up stationary electrostat
30. un 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 and supplemen tary air black Additional supply for OptiFlex 2 S 16 e Function description An additional OptiStar control unit complete with gun holder special powder supply cable and connecting ma terial An additional OptiSelect manual powder gun with gun ca ble powder hose rinsing air hose and standard nozzle set Pneumatic hoses for conveying air red supplementary air black as well as a pneumatic connection with dual distributor from pressure reducing valve to control unit Mains adaptor for twin equipment OptiFlex S manual coating equipment V 05 10 Technical Data Electrical Data OptiFlex S manual coating equipment iTw Gema OptiFlex S manual coating equipment Nominal input voltage VEA VAS Frequency 50 60 Hz Input value 150 VA Nominal output voltage to the gun max 12 V Nominal output current to the gun max 1 A Protection type IP54 0 40 C Temperature range 32 F 104 F Approvals Pneumatical Data OptiFlex S manual coating equipment Compressed air main connection G1 4 internal thread Max input pressure 10 bar Min input pressure 6 bar Max water vapor content of compressed air 1 3 g m Max oil vapor content of compressed air 0 1 mg m Max
31. wder 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 regulations for the operating firm and or operating personnel 1 Any operating met
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