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Summary of Contents for ITW Gema OptiFlex 2 B
- Page 1 Operating instructions and spare parts list Manual coating equipment OptiFlex 2 B Translation of the original operating instructions...
- Page 2 To the best of our knowledge and belief, the information contained in this publication was correct and valid on the date of publication. ITW Gema GmbH makes no representations or warranties with respect to the contents or use of this publication, and reserves the right to revise this publication and make changes to its content without prior notice.
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Page 3: Table Of Contents
Safety symbols (pictograms) ................... 3 Conformity of use ....................8 Product-specific safety measures ................8 OptiFlex 2 B manual coating equipment ............ 8 About this manual General information ....................9 Product description ... - Page 4 Spare parts list Ordering spare parts ..................... 37 OptiFlex 2 B manual coating equipment – Spare parts ........38 OptiFlex 2 B manual coating equipment – Spare parts ........39 OptiFlex 2 B – Pneumatic group................40 2 ...
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Page 5: General Safety Regulations
General safety regulations This chapter sets out the fundamental safety regulations that must be followed by the user and any third parties using OptiFlex 2 B manual coating equipment. These safety regulations must be read and understood in full before the OptiFlex 2 B is put into operation. - Page 6 ITW Gema GmbH General must be consulted prior to any use of the OptiFlex 2 B Manual coating Information equipment for purposes or substances beyond those stipulated in our guidelines.
- Page 7 The control units for the spray guns must be installed and used in zone 22. Spray guns are allowed in zone 21. Only original ITW Gema OEM parts are guaranteed to maintain the explosion protection rating. If damages occur related to the use of spare...
- Page 8 Smoking and open flames are forbidden in the entire plant area! No work that could potentially produce sparks is allowed! No smoking or open flames 6 General safety regulations OptiFlex 2 B...
- Page 9 The operating personnel should hold the gun with bare hands. If gloves are worn, these must also conduct electricity. These general safety regulations must be read and understood in all cases prior to start-up! General safety regulations 7 OptiFlex 2 B...
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Page 10: Conformity Of Use
V 05/11 Conformity of use 1. The OptiFlex 2 B manual coating equipment is state of the art equipment that conforms to the recognized technical safety regulations and is designed for normal powder coating applications. 2. Any other use is considered non-compliant. The manufacturer shall not be liable for damages resulting from such use;... -
Page 11: About This Manual
Information about the functionality of the individual system components - booth, gun control unit, manual gun or powder injector - should be referenced to their enclosed corresponding documents. About this manual 9 OptiFlex 2 B... -
Page 13: Product Description
V 05/11 Product description Field of application The OptiFlex 2 B (with powder box) manual coating equipment is exclusively intended for electrostatic coating using organic powders (For more on this please also review chapter "Technical Data"). Any other use is considered non-compliant. The manufacturer is not responsible for any incorrect use, and any associated risks are assumed by the user alone. -
Page 14: Reasonably Foreseeable Misuse
The Tribo gun the gun is not type approved (ATEX). ** Only for enamel powder, the gun is not type approved (ATEX). Warning: The OptiFlex 2 B manual coating equipment can only be used with the specified gun types! Powder output (guide values) -
Page 15: Guide Values For Optiflex 2 Cg09 With The Optiflow Ig06 Injector
The total air consists of conveying air and supplementary air, in relation to the selected powder quantity (in %). As a result the total air volume is maintained constant. Factory OptiFlex 2 B Range setting Flow rate - fluidizing air - OptiFlex B 0-1.0 Nm³/h... -
Page 16: Pneumatic Data
V 05/11 Pneumatic data OptiFlex 2 B Max. input pressure 10 bar Min. input pressure 6 bar Input pressure (Dynamic based on pressure 5.5 bar / 80 psi regulator setting) Max. water vapor content of the compressed 1.3 g/m³ Max. oil vapor content of the compressed air 0.1 mg/m³... -
Page 17: Design And Function
V 05/11 Design and function General view OptiFlex 2 B manual coating equipment - Structure 1 OptiFlex 2 CG09 control unit 10 Filter unit 2 OptiFlex 2 GM03 manual powder gun 11 Gun holder 3 OptiFlow injector 12 Hose holder... -
Page 18: Scope Of Delivery
Processing the powder directly from the original powder manufacturer's container The OptiFlex 2 B manual coating equipment allows for powder to be processed directly out of the original powder manufacturer's container. A titled vibrating floor has been included to ensure that the powder container empties itself completely. -
Page 19: Start-Up
Corresponding power and compressed air supply available Powder preparation and powder quality Set-up The OptiFlex 2 B manual coating equipment should always be set up vertically on a flat surface. WARNING The manual coating equipment must not under any circumstances be set up near a heat source (such as an enameling furnace) or an electromagnetic source (such as a control cabinet). -
Page 20: Mounting Instructions
V 05/11 Mounting instructions The OptiFlex 2 B manual coating equipment must be set up in accordance with the setup and connecting instructions (included with delivery). 18 Start-up OptiFlex 2 B... -
Page 21: Connection Instructions
PowerClean module Fluidizing/suction unit Connection instructions - overview The OptiFlex 2 B manual coating equipment must be connected in accordance with the setup and connection instructions (Please also review the operating instructions for the OptiFlex 2 CG09 manual gun control unit). - Page 22 V 05/11 Note: The compressed air must be free of oil and water! 20 Start-up OptiFlex 2 B...
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Page 23: Initial Start-Up
The remainder of the start-up procedure for the OptiFlex 2 GM03 manual powder gun is explicitly described in the operating instructions for the OptiFlex 2 CG09 manual powder gun control unit (chapter "Initial start-up" and "Daily start-up")! Initial start-up 21 OptiFlex 2 B... -
Page 24: Set Head Piece
(For more on this, please also see the operating instructions for the OptiFlex 2 CG09 manual gun control unit)! NOTE! The manual gun control unit always starts up to the last configured settings. 22 Initial start-up OptiFlex 2 B... -
Page 25: Operation
Description Presetting Powder output Total air 4.0 Nm³/h High voltage 80 kV 80 µA Spray current 0.1 Nm³/h Electrode rinsing air Fluidizing air 0.1 Nm³/h (for OptiFlex-B and S) Initial start-up 23 OptiFlex 2 B... - Page 26 Nm³/h. Die Gesamtluftmenge wird dabei automatisch von der Steuerung konstant gehalten If values are entered that the equipment cannot implement, then the operator is informed of this by a blinking in the relevant display and a temporary error message! 24 Initial start-up OptiFlex 2 B...
- Page 27 In moist or tropical environments, any moisture is driven from the injector, powder hose and powder gun. The LCD segments begin to move on the CG09 display Initial start-up 25 OptiFlex 2 B...
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Page 28: Setting The Background Illumination
PowerClean impulse by pressing the pistol trigger a second time After completion of the PowerClean procedure, the controller switches back to coating mode. Setting the background illumination 1. Press The display switches to the following level: Select the desired brightness 26 Initial start-up OptiFlex 2 B... -
Page 29: Color Change
When a color change takes place, the individual components of the manual coating equipment must be cleaned carefully. All powder particles of the former color must be removed during this process! The following describes an 'extreme' color change (light to dark). Initial start-up 27 OptiFlex 2 B... - Page 30 V 05/11 Remove and clean the nozzle purge gun using air 28 Initial start-up OptiFlex 2 B...
- Page 31 V 05/11 Initial start-up 29 OptiFlex 2 B...
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Page 32: Shutdown
If in disuse for several days 1. Separate from power mains 2. Clean the coating equipment (see the corresponding operating manual) 3. Turn off the compressed air main supply 30 Initial start-up OptiFlex 2 B... -
Page 33: Cleaning And Maintenance
Cleaning and maintenance Note: Regular and conscientious maintenance increases the service life of the OptiFlex 2 B manual coating equipment and provides for a longer continuous coating quality! The parts, which are to be replaced during maintenance work, are available as spare parts. These parts will be found in the... -
Page 34: Powder Hose Rinsing
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 32 Cleaning and maintenance OptiFlex 2 B... -
Page 35: Maintenance And Cleaning Of The Filter Unit
1. Unscrew the filter glass on the filter unit 2. Loose the cap screw 3. Remove the complete filter element 4. Replace the filter element 5. Clean the filter glass on the inside and install it again Cleaning and maintenance 33 OptiFlex 2 B... -
Page 37: Troubleshooting
Contact local Gema gun cable connection representative defective Remote control on Contact local Gema powder gun defective representative Powder does not The objects are Check grounding, adhere to object, improperly or reground at better Troubleshooting 35 OptiFlex 2 B... - Page 38 Vibrator not plugged in plug in Incorrect equipment Configure parameter P0 type configured (See operating instructions for the OptiFlex 2 CG09 manual gun control unit, Chapter "Initial Start-up – Setting Equipment Type") 36 Troubleshooting OptiFlex 2 B...
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Page 39: Spare Parts List
Ø 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! Spare parts list ... -
Page 40: Optiflex 2 B Manual Coating Equipment - Spare Parts
V 05/11 OptiFlex 2 B manual coating equipment – Spare parts CH09 gun control unit - complete (see corresponding operating manual) 1007 018 GM03 manual powder gun - complete (see corresponding user manual) 1008 070 IG06 injector - complete (see corresponding user manual) 1007 780 Pneumatic connection for conveying air - complete (incl. -
Page 41: Optiflex 2 B Manual Coating Equipment - Spare Parts
V 05/11 OptiFlex 2 B manual coating equipment – Spare parts 12, 13 OptiFlex 2 B manual coating equipment – Spare parts Spare parts list 39 OptiFlex 2 B... -
Page 42: Optiflex 2 B - Pneumatic Group
V 05/11 OptiFlex 2 B – Pneumatic group Pneumatic group - complete 1007 120 Filter cartridge - 20 µm 1007 325 OptiFlex 2 B – Pneumatic group 40 Spare parts list OptiFlex 2 B... - Page 43 V 05/11 Spare parts list 41 OptiFlex 2 B...
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