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Rev. 00 03/19

OptiFlex Pro B Spray

Maintenance / Repairs



41

Maintenance / Repairs

General information

The product was designed for a maintenance-free operation.

ATTENTION

Any unauthorized modifications and alterations to the product are

not permitted for safety reasons and exclude the manufacturer’s

liability for any resulting damage!

Regular and conscientious cleaning and maintenance increase

the service life of the product and ensure consistent high coating

quality!

– The parts to be replaced during maintenance work are available

as spare parts. These parts can be found in the appropriate

spare parts list!

Interval

Daily maintenance

1. Clean the application pump (see therefore the application pump user

manual)

2. Clean the powder gun (For more on this, please also review the user

manual for the manual gun)

3. Clean the powder hose; Please also review the section "Color

change"

Weekly maintenance

1. Clean fluidizing/suction unit, application pump and powder gun.

– Place the fluidizing/suction unit back into 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 conveyor chain

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Содержание OptiFlex Pro B Spray

Страница 1: ...Rev 00 1017 932 EN Operating instructions and Spare parts list Manual equipment OptiFlex Pro B Spray Translation of the original operating instructions ...

Страница 2: ...s of Gema Switzerland 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 concerned approve of or are bound in any form by this manual We have endeavored to retain the preferred spelling of the trademarks and registered tr...

Страница 3: ...ucture 17 Overall view 17 Scope of delivery 18 Typical characteristics properties of the functions 18 Processing the powder directly from the original powder manufacturer s container 18 Freely rotating head piece 18 Technical Data 19 Connectable guns 19 Electrical data 19 Pneumatic data 19 Dimensions 20 Processible powders 20 Powder output reference values 20 Air flow rates 20 Environmental condit...

Страница 4: ...Type of storage 39 Storage duration 39 Space requirements 39 Physical requirements 40 Maintenance during storage 40 Maintenance schedule 40 Maintenance works 40 Maintenance Repairs 41 General information 41 Interval 41 Daily maintenance 41 Weekly maintenance 41 If in disuse for several days 42 Gun maintenance 42 Maintenance of the filter unit 42 Cleaning 43 Gun cleaning 43 Cleaning the fluidizing ...

Страница 5: ...Rev 00 03 19 OptiFlex Pro B Spray Table of contents 5 Diffuser OptiSelect 54 Pneumatic group 55 ...

Страница 6: ......

Страница 7: ...g manual describes all options and functions of this manual coating equipment Please note that your manual coating equipment may not be equipped with all described functions Options are marked by double asterisks Keeping the Manual Please keep this Manual ready for later use or if there should be any queries Safety symbols pictograms The following warnings with their meanings can be found in the G...

Страница 8: ...for the environment MANDATORY NOTE Information which must be observed NOTICE Useful information tips etc Structure of Safety Notes Every note consists of 4 elements Signal word Nature and source of the danger Possible consequences of the danger Prevention of the danger SIGNAL WORD Nature and source of the hazard Possible consequences of the danger Prevention of the danger Presentation of the conte...

Страница 9: ...Safety regulations Work should only be carried out in accordance with the instructions of the relevant documents Always work with the complete original document Basic safety instructions This product is built to the latest specification and conforms to the recognized technical safety regulations and is designed for the normal application of powder coating Any other use is considered non compliant ...

Страница 10: ...regulations must be read and understood in all cases prior to start up General information This product is built to the latest specification and conforms to the recognized technical safety regulations and is designed for the normal application of powder coating Any other use is considered non compliant The manufacturer shall not be liable for damage resulting from such use the user bears sole resp...

Страница 11: ... 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 The product may not be switched on until the booth is in operation If the booth stops the product must switch off too Explosion hazard The control units for the spray guns mus...

Страница 12: ... 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 electrostatic manual powder coating equipment The grounding cable must have a good metallic conn...

Страница 13: ...r The plug connections between the powder spraying equipment and the mains should only be removed when the power supply is switched off As far as it is necessary the operating firm must ensure that the operating personnel wear protective clothing e g facemasks A dust mask corresponding to filter class FFP2 or N95 at minimum must be worn during any cleaning work The operating personnel must wear el...

Страница 14: ...Rev 00 03 19 14 Safety OptiFlex Pro B Spray ...

Страница 15: ... service and maintenance instructions specified by the manufacturer is also part of conformity of use This product should only be used maintained and started up by trained personnel who are informed about and are familiar with the possible hazards involved Any other use is considered non compliant The manufacturer is not responsible for any incorrect use and the risks associated with such actions ...

Страница 16: ...h film builds With a powder output of up to 300 g min and an extremely high efficiency best coating results are achieved Application Precise powder transport Option I Ia Extension Kit Number of guns 1 1 1 Number of pumps 1 1 1 Powder output 1x 50 300 g min 2x 50 300 g min Reasonably foreseeable misuse Operation without the proper training Use with insufficient compressed air quality and grounding ...

Страница 17: ...er 13 Vibrating table 14 Diffuser OptiSelect Pro GM04 manual powder gun All information about the OptiSelect Pro GM04 manual powder gun can be found in the documentation for that equipment enclosed with this manual OptiStar 4 0 Gun control unit All information about the OptiStar 4 0 Type CG23 P manual gun control unit can found in the documentation for that equipment enclosed with this manual Opti...

Страница 18: ...eumatic hoses for transport air blue spraying air black pinch valve air green and fluidizing air black Operating manual Short description Typical characteristics properties of the functions Processing the powder directly from the original powder manufacturer s container The type B manual coating equipment allows for powder to be processed directly out of the original powder manufacturer s containe...

Страница 19: ...0 240 VAC Frequency 50 60 Hz Fluctuations of the power supply 10 Overvoltage category OVC II Connected load 140 VA Nominal output voltage to the gun 12 V Nominal output current to the gun 1 2 A Connection and output for vibrator on Aux output 100 240 VAC max 100 W Connection for rinsing function valve 24 VDC max 3 W Protection type IP54 Approvals II 3 D preset country specific voltage Pneumatic da...

Страница 20: ... total air volume is maintained constant OptiFlex Pro B Spray Range Factory setting Flow rate fluidizing air Device type B 0 1 0 Nm h 0 1 Nm h Device type F without AirMover air requirements 0 5 0 Nm h 1 0 Nm h Electrode rinsing air flow rate 0 5 0 Nm h 0 1 Nm h Flow rate total air at 5 5 bar 5 Nm h Transport air flow rate 0 5 5 Nm h Spraying air flow rate 0 5 5 Nm h The max total air consumption ...

Страница 21: ...ee of pollution of the intended environment 2 in accordance with DIN EN 61010 1 Sound pressure level OptiFlex Pro B Spray Normal operation 60 dB A The sound pressure level was measured while the unit was in operation measurements were taken at the most frequent operator positions and at a height of 1 7 m from the ground The specified value is applicable only for this product itself and does not ta...

Страница 22: ...Rev 00 03 19 22 Product description OptiFlex Pro B Spray ...

Страница 23: ...rrounding temperature too high Install the equipment only in locations with an ambient temperature of between 5 and 40 C i e never next to heat sources such as an enameling furnace or electromagnetic sources such as a control cabinet Assembly guide The manual coating equipment must be set up in accordance with the setup and connecting instructions included with delivery fig 5 ...

Страница 24: ... the manufacturer Just a few cables and hoses must be connected fig 6 Connecting guide overview 1 Electrode rinsing air hose 2 Powder hose 3 Gun cable 4 Pinch valve air hose 5 Spraying air hose 6 Transport air hose 7 Control signal cable 8 Application pump no 1 8 1 Application pump no 2 9 Fluidizing suction tube 10 Compressed air hose 12 Fluidizing air hose ...

Страница 25: ... grounding cable to the booth or the suspension arrangement Check ground connections with Ohm meter and ensure 1 MOhm or less The compressed air must be free of oil and water Close the unused connections with the provided dust protection caps Set head piece 1 2 3 4 ...

Страница 26: ...Rev 00 03 19 26 Assembly Connection OptiFlex Pro B Spray ...

Страница 27: ...ons When starting up the gun control unit the following general conditions impacting the coating results must be taken into consideration Gun correctly connected Gun control unit correctly connected Corresponding power and compressed air supply available Powder preparation and powder quality OK ...

Страница 28: ...ed in the operating instructions for the OptiStar CGxx manual powder gun control unit chapter Initial start up and Daily start up Setting the device type If the control unit is supplied as a component of a manual coating unit then the corresponding system parameter is set correctly by the factory ATTENTION A wrong parameterization leads to various malfunctions For more on this please also see the ...

Страница 29: ... with a sufficiently powerful suction unit then the stirred up dust from the coating powder can cause respiratory issues or cause a slippage falling hazard The manual equipment may only be operated in conjunction with a sufficiently powerful suction unit such as Gema Classic Open booth 1 Swivel aside the fluidizing suction unit 2 Place the open powder container on the vibrating table CAUTION Hand ...

Страница 30: ...tal air powder output and electrode rinsing air can be individually defined and are saved in the programs Starting the individual adjustable programs 1 Turn on the gun control unit with the ON key 2 Press the program key 3 Select the desired program 01 20 Program 20 active 4 Change the coating parameters as required Programs 01 20 are preset at the factory but can be modified at any time after whi...

Страница 31: ...er output value will be reached As a factory default value a powder rate of 60 and a total air volume of 4 Nm h are recommended If values are entered that the gun control unit cannot implement then the operator is informed of this by a blinking in the relevant display and a temporary error message Setting the total air volume 1 Adjust the total air volume on the gun control unit with the T3 T4 key...

Страница 32: ... avoided an overly high powder volume where possible 2 Check fluidization of the powder in the powder container 3 Point the gun into the booth switch the gun on and visually check the powder output Setting the spraying air The spraying air ZL will be set in accordance to the calculated transport air TL and the adjusted total air volume GL Formula GL ZL TL fig 8 Air streams in the diffuser adapter ...

Страница 33: ...e correct electrode rinsing air according to the applied nozzles deflector plate flat jet nozzle 0 1 Nm h 0 5 Nm h too much electrode rinsing air 3 If in this display level is no operation for 3 seconds the first display level is switched over independently ...

Страница 34: ...ith a pressure of max 4 bar Cleaning the hose to the gun CAUTION Large dust formation possible The conveying hose and the powder gun must be pointed into the booth during the cleaning procedure In this cleaning program key T14 the powder hose to the gun will be cleaned with several air blasts During this time the pinch valve on the suction side remains closed Cleaning the hose on the suction side ...

Страница 35: ...problems Manual coating equipment type B Lift the fluidizing suction unit Point the fluidizing suction unit and the gun into a suction unit or into the booth Manual coating equipment type F Remove the hose feedthrough from the powder hopper Point the hose feedthrough and the gun into a suction unit or into the booth 1 OR 2 Select the corresponding cleaning program OR OR 3 START The automated clean...

Страница 36: ...alve diagnostic The pinch valve diagnostic is to be carried out in order to maintain the coating quality or after the error message H89 is displayed The prerequisites for the diagnostic Exhaust at suction and conveyance side must be present and in operation Powder hopper must be empty Cleaning program completed The pinch valve diagnostic is to start after the cleaning program has been completed 1 ...

Страница 37: ...If the error message H87 H187 suction pinch valve or H88 H188 conveying pinch valve is displayed after the procedure has been completed the corresponding pinch valve hoses must be replaced see AP01 Application pump Operating manual Setting the background illumination 1 Press the key The display switches to the following level 2 Select the desired brightness ...

Страница 38: ...suction unit 2 Lift the fluidizing suction unit 3 Point the gun into a suction unit or into the booth 4 Activate the cleaning mode either on the rear of the powder gun remote control or on the control unit 5 Select the corresponding cleaning program See chapter Activating the cleaning function on page 35 6 Press the gun trigger The automated cleaning procedure is started After completion of the cl...

Страница 39: ...powder hose see therefore the corresponding user manuals 3 Turn off the compressed air main supply Storage conditions Hazard notes There is no danger to personnel or the environment if the unit is stored properly Type of storage For safety reasons the product should only be stored in a vertical position Storage duration If the physical conditions are maintained the unit can be stored indefinitely ...

Страница 40: ...ements Storage must be inside a dry building at a temperature between 5 and 50 C Do not expose to direct sunlight Maintenance during storage Maintenance schedule No maintenance schedule is necessary Maintenance works During long term storage periodically perform a visual check ...

Страница 41: ...ced during maintenance work are available as spare parts These parts can be found in the appropriate spare parts list Interval Daily maintenance 1 Clean the application pump see therefore the application pump user manual 2 Clean the powder gun For more on this please also review the user manual for the manual gun 3 Clean the powder hose Please also review the section Color change Weekly maintenanc...

Страница 42: ...e again to the hose connection on the application pump Gun maintenance The gun is designed to require only a minimum amount of maintenance 1 Clean the gun with dry cloth see chapter Maintenance 2 Check connection points to powder house 3 Replace the powder hoses if necessary Maintenance of the filter unit The filter unit on the manual coating equipment measures and cleans the compressed air This i...

Страница 43: ... turpentine tetrachloromethane toluene trichloroethylene xylene Only cleaning agents with a flash point of a least 5 Kelvin above the ambient temperature or cleaning places with technical ventilation are allowed Before cleaning the powder gun switch off the control unit The compressed air used for cleaning must be free of oil and water Daily 1 Blow off the outside of the gun and wipe clean etc Wee...

Страница 44: ... unit 5 Reconnect the suction hose Repair work In the event of malfunctions or faults the product must be checked and repaired by an authorized Gema service workshop The repairs must only be performed by an authorized specialist Improper tampering can result in serious danger for user and equipment Periodic checks The periodic checks include examining all connecting cables and hoses The correspond...

Страница 45: ...Power pack defective Contact local Gema representative Gun LED remains dark although the gun is triggered High voltage adjustment is set too low Increase high voltage Gun plug or gun cable defective Contact local Gema representative LED on gun defective Contact local Gema representative Powder does not adhere to object although the gun is triggered and sprays powder High voltage and current deacti...

Страница 46: ...cation pump Pinch valve hose in the application pump worn Replace Fluidization not running see below No electrode rinsing air Rinsing air throttle motor defective Contact local Gema representative The powder is not fluidized Compressed air not present Connect the equipment to the compressed air Fluidizing air is set too low on the control unit Adjust the fluidization correctly Throttle motor defec...

Страница 47: ... by Gema the instructions in the respective manufacturer s documentation must be observed Disposal regulations The product must be disassembled and disposed of properly at the end of its service life When disposing of the product the applicable local and regional laws directives and environmental regulations must be complied with Materials The materials must be sorted according to material groups ...

Страница 48: ...Rev 00 03 19 48 Disposal OptiFlex Pro B Spray ...

Страница 49: ...18 15 mm When ordering cable or hose material the required length must also be given The spare part numbers of this bulk stock is always marked with an Wearing parts are always marked with a All dimensions of plastic hoses are specified with the external and internal diameter Example Ø 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d ATTENTION Use of non original Gema spare parts When usi...

Страница 50: ...70 8 Swivel wheel Ø 50 mm 260 606 9 Rubber damper Ø 20x25 mm M6 2 mm 246 000 10 Spacing ring 375 624 11 Vibrator 220 240 V 50 Hz 1 6 m 1008 919 Vibrator 110 V 50 Hz 1 6 m 1008 920 Vibrator 1 V 60 Hz 1 6 m 10 9 12 Rubber wheel Ø 200 mm 260 592 13 Hose clamp Ø 15 18 mm 203 386 14 Quick release connection NW7 8 Ø 10 mm 239 267 15 Pneumatic group complete see corresponding spare parts list 16 AP01 App...

Страница 51: ...Rev 00 03 19 OptiFlex Pro B Spray Spare parts list 51 OptiFlex Pro B Spray Spare parts fig 10 ...

Страница 52: ...oot piece 1014 667 10 Connector with flow restrictor Ø 0 3 mm 1006 556 11 O ring Ø 8x2 mm 242 470 12 Suction restriction piece 1014 668 13 O ring Ø 5 1x1 6 mm 1014 669 14 Guide sleeve 1007 094 15 Locknut M36x1 5 mm 1007 095 16 Retaining bracket 1008 083 17 Cable bush Ø 4 8 1 5 mm 265 276 18 Bearing bush 1017 813 19 O ring Ø 20x2 mm 1017 809 A Pneumatic connection for fluidizing air complete not sh...

Страница 53: ...Rev 00 03 19 OptiFlex Pro B Spray Spare parts list 53 Fluidizing suction tube spare parts fig 11 Fluidizing suction tube spare parts ...

Страница 54: ...1 Adaptor piece 1011 636 2 O ring Ø 12x1 5 mm 1000 822 3 O ring Ø 13x1 5 mm 1009 943 4 Fluidizing tube 1005 262 5 Connector 1011 634 6 Screw in nipple M7 Ø 6 mm 1008 699 7 Plastic tube Ø 6 4 mm 103 144 8 Plug in connector Ø 6 Ø 8 mm 254 894 Please indicate length Wearing part fig 12 Diffuser OptiSelect ...

Страница 55: ...in valve 1008 238 3 Connector NW7 4 1 4 256 730 4 Elbow joint 1 4 1 4 222 674 5 Sealing plug 1 8 203 297 6 R F unit 0 8 bar 1 4 complete incl pos 1 and 2 1008 236 7 Double nipple 1 4 1 4 divisible 261 165 8 Pressure gauge 0 10 bar 1 8 1008 049 9 Distribution block 1017 816 10 Screw in nipple 1 4 Ø 8 mm 265 136 11 Plug Ø 8 mm 238 023 Wearing part fig 13 Pneumatic group ...

Страница 56: ......

Страница 57: ...cal data 19 Environmental conditions 21 F Fault clearance 45 Figure references in the text 8 I Intended use 15 M Maintenance 41 Maintenance during storage 40 O Operation 29 P Periodic checks 44 Pictograms 7 Pneumatic data 19 Powder output reference values 20 Presentation of the contents 8 Product description 15 Product specific security regulations 10 R Rating plate 21 Repair work 44 Repairs 41 S ...

Страница 58: ...Rev 00 ...

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