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Summary of Contents for ITW Gema OptiFlex 2 C
- Page 1 Operating instructions and spare parts list Manual coating equipment OptiFlex 2 C 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 C Manual coating equipment ............ 8 About this manual General information ....................9 Product description ... - Page 4 Spare parts list Ordering spare parts ..................... 35 OptiFlex 2 C manual coating equipment - Spare Parts List ......... 36 OptiFlex 2 C manual coating equipment - Spare Parts ........37 OptiFlex 2 C - Pneumatic group ................38 ...
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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 third parties using OptiFlex 2 C manual coating equipment. These safety regulations must be read and understood in full before the OptiFlex 2 C is put into operation. - Page 6 V 06/11 The OptiFlex 2 C 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. Any other use is considered non-compliant. The manufacturer shall not be liable for damage resulting from such use;...
- 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 igniting fire are forbidden in the entire vicinity of the system! No work that could potentially produce sparks is allowed! Fire and smoke prohibition 6 General safety regulations OptiFlex 2 C...
- 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 C...
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Page 10: Conformity Of Use
V 06/11 Conformity of use 1. The OptiFlex 2 C 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 damage 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 C... -
Page 13: Product Description
V 06/11 Product description Field of application The OptiFlex 2 C (with application cup) 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... -
Page 14: Reasonably Foreseeable Misuse
OptiFlex 2 C connectable OptiFlex 2 GM03 Warning: The OptiFlex 2 C manual coating equipment can only be used with the specified gun type! Air flow rates 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. -
Page 15: Electrical Data
V 06/11 Electrical data OptiFlex 2 C Nominal input voltage 100-240 VAC Frequency 50 -60 Hz Connected load 40 VA Nominal output voltage (to the gun) eff.10 V Nominal output current (to the gun) max. 1.2 A 24 VDC Connection for rinsing function (valve) max. -
Page 16: Design And Function
V 06/11 Design and function General view OptiFlex 2 C manual coating equipment - Setup 1 OptiFlex 2 CG09 control unit 10 Filter unit 2 OptiFlex 2 GM03 manual powder gun 11 Gun holder 3 Application cup 14 Shelf 4 Base... -
Page 17: Scope Of Delivery
OptiFlex 2 GM03 manual powder gun) Operating manual Short instructions Typical properties - Characteristics of the functions Processing the powder from the application cup The OptiFlex 2 C manual coating equipment processes powder from the application cup. Product description 15 OptiFlex 2 C... -
Page 19: Start-Up
V 06/11 Start-up Preparation for start-up Basic conditions When starting up the OptiFlex 2 C manual coating unit, the following general conditions impacting the coating results must be taken into consideration: Manual coating equipment is set up properly Gun control unit correctly connected... -
Page 20: Mounting Instructions
V 06/11 Mounting instructions The OptiFlex 2 C manual coating equipment must be set up in accordance with the setup and connecting instructions (included with delivery). OptiFlex 2 C Manual coating equipment Connection instructions Application cup Filter unit Connection instructions - overview... - Page 21 Use clamp to connect grounding cable to the cabin or the suspension arrangement. Check ground connections with Ohm meter and ensure 1 MOhm or less! Note: The compressed air must be free of oil and water! Start-up 19 OptiFlex 2 C...
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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 C... -
Page 24: Setting The Device Type
(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 C... -
Page 25: Operation
Select desired program (01-20) b) Change coating parameters as required Note: Programs 01-20 are preset at the factory but can be modified at any time, after which they are automatically stored. Initial start-up 23 OptiFlex 2 C... - Page 26 A total air volume of 4 Nm³/h and a 50% powder share are recommended as the base values. 9. Adjust the powder output volume (e.g. according to the desired coating thickness) much powder little powder 24 Initial start-up OptiFlex 2 C...
- Page 27 11. Point the gun into the booth (not at the object to be coated), press the gun trigger and visually check the powder output 12. Check whether everything is functioning correctly 13. Coating 14. Adjust the coating parameters as necessary Initial start-up 25 OptiFlex 2 C...
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Page 28: Setting The Background Illumination
1. Clean the application cup (see therefore the application cup user manual) 2. Dismantle and clean the powder gun (see therefore the user manual of the Manual powder gun) 3. Prepare the manual coating equipment with new powder for start-up 26 Initial start-up OptiFlex 2 C... -
Page 29: Shutdown
If in disuse for several days 1. Separate from power mains 2. Clean coating apparatus (see Chapter on "Cleaning and maintenance") 3. Turn off the compressed air main supply Initial start-up 27 OptiFlex 2 C... -
Page 31: Cleaning And Maintenance
Cleaning and maintenance Note: Regular and conscientious maintenance increases the service life of the OptiFlex 2 C 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 32: Cleaning
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 30 Cleaning and maintenance OptiFlex 2 C... -
Page 33: Maintenance And Cleaning Of The Filter Unit
Please also review the user manual for the OptiFlex 2 GM03 manual powder gun! Maintenance and cleaning of the filter unit The filter unit on the OptiFlex 2 C manual coating equipment measures and cleans the compressed air. This is where the equipment's main compressed air connection is located. -
Page 35: Troubleshooting
Dip tube clogged Blow through the dip tube with compressed air and place it in the powder carefully Total air incorrectly Set total air correctly configured (Default value 4 Nm³/h) Main valve defective Replace main valve Troubleshooting 33 OptiFlex 2 C... - Page 36 Powder fluidization Dismantle and clean the insufficient or not fluidizing plate, replace available if necessary No electrode rinsing air Rinsing air throttle motor Contact local Gema defective representative 34 Troubleshooting OptiFlex 2 C...
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Page 37: 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 38: Optiflex 2 C Manual Coating Equipment - Spare Parts List
V 06/11 OptiFlex 2 C manual coating equipment - Spare Parts List CG09 gun control unit - complete (see corresponding operating manual) 1007 018 GM03 manual powder gun - complete (see corresponding user manual) 1008 070 1002 069 Application cup 500 ml - complete (see corresponding user manual) Pneumatic connection for conveying air - complete (incl. -
Page 39: Optiflex 2 C Manual Coating Equipment - Spare Parts
V 06/11 OptiFlex 2 C manual coating equipment - Spare Parts OptiFlex 2 C manual coating equipment - Spare Parts Spare parts list 37 OptiFlex 2 C... -
Page 40: Optiflex 2 C - Pneumatic Group
V 06/11 OptiFlex 2 C - Pneumatic group Pneumatic group - complete 1007 120 Filter cartridge - 20 µm 1007 325 OptiFlex 2 C - Pneumatic group 38 Spare parts list OptiFlex 2 C... - Page 41 V 06/11 Spare parts list 39 OptiFlex 2 C...
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