Rev. 00 1011 512 En
Pos: 2 /Titelseite ++++ Für alle Anleitungen ++++/Titelseite @ 1\mod_1452682577434_170.docx @ 22973 @ @ 1
Operating instructions and Spare parts list
Pneumatic-fluidizing unit OptiAir CA12
Translation of the original operating instructions === Ende der Liste für Textmarke Titelblatt ===
Rev. 00 02/16
Pos: 4 /Copyright ++++ Für alle Anleitungen ++++/Copyright @ 1\mod_1452682618687_170.docx @ 22999 @ @ 1
Documentation OptiAir CA12
© Copyright 2016 Gema Switzerland GmbH
All rights reserved.
This publication is protected by copyright. Unauthorized copying is prohibited 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 Gema Switzerland GmbH.
MagicCompact, MagicCylinder, MagicPlus, MagicControl, OptiFlex, OptiControl, OptiGun, OptiSelect, OptiStar and SuperCorona are registered trademarks of Gema Switzerland GmbH.
OptiFlow, OptiCenter, OptiMove, OptiSpeeder, OptiFeed, OptiSpray, OptiSieve, OptiAir, OptiPlus, OptiMaster, MultiTronic, EquiFlow, Precise Charge Control (PCC), Smart Inline Technology (SIT) and Digital Valve Control (DVC) are trademarks 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 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 publication. Gema Switzerland 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.
For the latest information about Gema products, visit www.gemapowdercoating.com.
For patent information, see www.gemapowdercoating.com/patents or www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH Mövenstrasse 17 9015 St.Gallen Switzerland
Phone: +41-71-313 83 00 Fax.: +41-71-313 83 83
E-mail: [email protected]
=== Ende der Liste für Textmarke Copyright ===
Rev. 00 02/16
OptiAir CA12 Table of contents 3
Pos: 6 /Inhaltsverzeichnis ++++ Für alle Anleitungen ++++/Inhaltsverzeichnis @ 1\mod_1452682645125_170.docx @ 23026 @ @ 1
Table of contents
About this instructions 5
General information ................................................................................................ 5 Keeping the Manual ................................................................................................ 5 Safety symbols (pictograms) ................................................................................... 5 Presentation of the contents ................................................................................... 6
Figure references in the text ...................................................................... 6
Safety 7
Intended use ........................................................................................................... 7 Product specific security regulations ...................................................................... 7
Product description 9
Field of application .................................................................................................. 9 Reasonably foreseeable misuse ................................................................ 9
Technical data ......................................................................................................... 9 Pneumatic data .......................................................................................... 9 Dimensions ................................................................................................ 9
Structure ................................................................................................................ 10 Principle of operation ............................................................................................ 10
Assembly / Connection 11
Connecting the Pneumatic-fluidizing unit .............................................................. 11
Operation 11
Setting the fluidization ........................................................................................... 12 Setting the Airmover air ........................................................................................ 13
Spare parts list 15
Ordering spare parts ............................................................................................. 15 OptiAir CA12-A (for use with HF50/HF100 powder hopper) – spare parts list ..... 16 OptiAir CA12-A (for use with HF50/HF100 powder hopper) – spare parts .......... 17 OptiAir CA12-B (for use with HF150/HF200 powder hopper) – spare parts list ... 18 OptiAir CA12-B (for use with HF150/HF200 powder hopper) – spare parts ........ 19
=== Ende der Liste für Textmarke Inhaltsverzeichnis ===
Pos: 8 /Steuermodule ++++ Für alle Anleitungen ++++/++++++++ Seitenumbruch ++++++++ @ 1\mod_1452608869481_0.docx @ 22162 @ @ 1
Rev. 00 02/16
4 About this instructions OptiAir CA12
Pos: 10 /Überschriften ++++ Für alle Anleitungen ++++/1. Ebene/Über diese Anleitung @ 1\mod_1452608729182_170.docx @ 22133 @ 1 @ 1
Rev. 00 02/16
OptiAir CA12 About this instructions 5
About this instructions
Pos: 11 /Kapitel/Über diese Anleitung ++++ Für alle Anleitungen ++++/Allgemeines @ 1\mod_1452610204952_170.docx @ 22326 @ 2 @ 1
General information This operating manual contains all important information which you require for the working with the OptiAir CA12. 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 functional mode of the individual system components should be referenced in the respective enclosed documents.
Pos: 12 /Kapitel/Über diese Anleitung ++++ Für alle Anleitungen ++++/Anleitung aufbewahren @ 1\mod_1452679788745_170.docx @ 22537 @ 2 @ 1
Keeping the Manual Please keep this Manual ready for later use or if there should be any queries.
Pos: 13 /Kapitel/Über diese Anleitung ++++ Für alle Anleitungen ++++/Sicherheitssymbole (Piktogramme) @ 1\mod_1452781244678_170.docx @ 23723 @ 2 @ 1
Safety symbols (pictograms)
The following warnings with their meanings can be found in the Gema operating instructions. The general safety precautions must also be followed as well as the regulations in the relevant operating instructions.
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Rev. 00 02/16
6 About this instructions OptiAir CA12
ATTENTION
Indicates a potentially harmful situation. If not avoided, the equipment or something in its surrounding may be damaged.
ENVIRONMENT
Indicates a potentially harmful situation which, if not avoided, may have harmful consequences for the environment.
Notice
<Useful information, tips, etc.>
Pos: 14 /Kapitel/Über diese Anleitung ++++ Für alle Anleitungen ++++/Darstellung des Inhalts @ 1\mod_1452784296568_170.docx @ 23802 @ 23 @ 1
Presentation of the contents
Figure references in the text
Figure references are used as cross references in the descriptive text.
Example:
"The high voltage (H) created in the gun cascade is guided through the center electrode."
Pos: 16 /Überschriften ++++ Für alle Anleitungen ++++/1. Ebene/Sicherheit @ 1\mod_1452680111994_170.docx @ 22563 @ 1 @ 1
Rev. 00 02/16
OptiAir CA12 Safety 7
Safety
Pos: 17 /Kapitel/Sicherheit/Bestimmungsgemässe Verwendung/Bestimmungsgemässe Verwendung @ 1\mod_1452781705430_170.docx @ 23749 @ 2 @ 1
Intended use
– 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 responsibility for such actions. If this product is to be used for other purposes or other substances outside of our guidelines then Gema Switzerland GmbH should be consulted.
– Observance of the operating, 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.
– Start-up (i.e. the execution of intended operational tasks) is forbidden until it has been established that this product has been set up and wired according to the guidelines for machinery. The standard "Machine safety" must also be observed.
– Unauthorized modifications to the product exempt the manufacturer from any liability 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 also must be observed.
Pos: 18 /Kapitel/Sicherheit/Produktspezifische Sicherheitshinweise/Produktspezifische Sicherheitshinweise @ 1\mod_1452782586999_170.docx @ 23776 @ 2 @ 1
Product specific security regulations
– This product is a constituent part of the equipment and is therefore integrated in the system's safety concept.
– If it is to be used in a manner outside the scope of the safety concept, then corresponding measures must be taken.
– The installation work to be done by the customer must be carried out according to local regulations.
Rev. 00 02/16
8 Safety OptiAir CA12
– It must be ensured, that all components are earthed according to the local regulations before start-up.
Notice
For further security information, see the more detailed Gema safety regulations!
Pos: 19 /Warnhinweise ++++ Für alle Anleitungen ++++/WARNUNG/Arbeiten ohne Betriebsanleitung @ 1\mod_1452779639975_170.docx @ 23690 @ @ 1
WARNING
Working without operating instructions
Working without operating instructions or with individual pages from the operating instructions may result in damage to property and personal injury if relevant safety information is not observed.
– Before working with the device, organize the required documents and read the section "Safety regulations".
– Work should only be carried out in accordance with the instructions of the relevant documents.
– Always work with the complete original document.
Pos: 21 /Überschriften ++++ Für alle Anleitungen ++++/1. Ebene/Produktbeschreibung @ 1\mod_1452609707048_170.docx @ 22297 @ 1 @ 1
Rev. 00 02/16
OptiAir CA12 Product description 9
Product description
Pos: 22 /Kapitel/Produktbeschreibung/Equipment and Controls/Air Controls/Anwendungsgebiet CA12 @ 1\mod_1461239846679_170.docx @ 27598 @ 2 @ 1
Field of application The Pneumatic-fluidizing unit distributes the compressed air to the gun control units and regulates the fluidizing air and Airmover pressure.
Pos: 23 /Kapitel/Produktbeschreibung/Equipment and Controls/Air Controls/vorhersehbare Fehlanwendung-CA12 @ 1\mod_1461574020294_170.docx @ 29348 @ 3 @ 1
Reasonably foreseeable misuse
– Use with insufficient compressed air quality
– Input pressure too low Pos: 24 /Kapitel/Produktbeschreibung/Equipment and Controls/Air Controls/Technische Daten CA12 @ 1\mod_1461240247601_170.docx @ 27624 @ 233 @ 1
Technical data
Pneumatic data
OptiAir CA12
Input pressure 7-10 bar / 101-145 psi
Compressed air consumption dependent on the number of connected guns
Water vapor content max. 1.3 g/m³
Oil content max. 0.1 mg/m³
Protection type IP54
Approvals II 3D
Dimensions
OptiAir CA12
Width 173 mm
Height 177 mm
Depth 290 mm
Weight 2.2 kg (CA12-A)
2.8 kg (CA12-B)
Pos: 25 /Kapitel/Produktbeschreibung/Equipment and Controls/Air Controls/Aufbau CA12 @ 1\mod_1461240624493_170.docx @ 27734 @ 2 @ 1
Rev. 00 02/16
10 Product description OptiAir CA12
Structure
fig. 1: Structure
1 Pressure indicator for fluidizing air
2 Prefluidization press button
3 Pressure indicator for Airmover
4 Pressure regulator for Airmover
5 Pressure regulator for fluidizing air
Pos: 26 /Kapitel/Produktbeschreibung/Equipment and Controls/Air Controls/Funktionsprinzip CA12 @ 1\mod_1461243031932_170.docx @ 27760 @ 2 @ 1
Principle of operation The prefluidization is switched on manually by pressing the Prefluidization key. The fluidization operates directly by connecting the Pneumatic-fluidizing unit to the compressed air.
The fluidizing air produces an overpressure in the powder hopper. This overpressure prevents the powder supply and must be eliminated. For this purpose an Airmover is installed on the powder hopper, which extracts, similarly as an injector, the overpressure and the powder mixed with air.
Therefore, the Airmover produces a depression in the powder hopper. The air volume, which can be extracted by the Airmover, depends on the powder hopper size and the fluidizing air volume.
Pos: 28 /Überschriften ++++ Für alle Anleitungen ++++/1. Ebene/Montage / Anschluss @ 1\mod_1452680195484_170.docx @ 22617 @ 1 @ 1
Rev. 00 02/16
OptiAir CA12 Assembly / Connection 11
Assembly / Connection
Pos: 29 /Kapitel/Montage / Anschluss/Equipment and Controls/Air Controls/Anschliessen der CA12 @ 1\mod_1461243417741_170.docx @ 27786 @ 2 @ 1
Connecting the Pneumatic-fluidizing unit The Pneumatic-fluidizing unit is delivered ready-to-use by the manufacturer. Just a few hoses must be connected additionally.
NOTICE
The compressed air must be free of oil and water!
The Pneumatic-fluidizing unit is connected as follows:
1. Connect the fluidizing air hose to the output 3 and to the corresponding connection on the powder hopper
2. Connect the Airmover hose to the output 1 and to the Airmover
3. Connect the compressed air supply hose to the connection 2 (Air supply IN)
fig. 2: Connections
1 Output to the Airmover
2 Compressed air main connection
3 Fluidizing air connection to the powder hopper
Pos: 31 /Überschriften ++++ Für alle Anleitungen ++++/1. Ebene/Bedienung / Betrieb @ 1\mod_1452680450846_170.docx @ 22698 @ 1 @ 1 Operation Pos: 32 /Kapitel/Bedienung / Betrieb/Equipment and Controls/Air Controls/Fluidisierung einstellen-CA12 @ 1\mod_1461246415759_170.docx @ 27814 @ 2 @ 1
Rev. 00 02/16
12 Assembly / Connection OptiAir CA12
Setting the fluidization The powder fluidization depends on the powder type, the air humidity and the ambient temperature.
The Pneumatic-fluidizing unit contains a push button for the prefluidization, as well as a pressure regulator and a pressure gauge for fluidizing air and Airmover.
Notice
The Pneumatic-fluidizing unit is connected to a 7-10 bar compressed air circuit.
The fluidization is set as follows:
1. Connect the main compressed air supply and open it.
The compressed air flows now through the Pneumatic-fluidizing unit. The fluidization operates immediately when connecting the Pneumatic-fluidizing unit to the compressed air
2. Adjust the compressed air to 6 bar on the pressure reducing valve (5)
3. Check the powder fluidization in the powder hopper.
If the powder does not "boil" regularly, push the prefluidization button (2) several times briefly. The compressed air of the prefluidization will "loosen up" the powder.
If the powder begins to "boil", adjust the fluidizing air with the corresponding pressure regulator in such a way that the "boiling" spreads evenly on the powder surface.
The fluidizing air pressure is monitored on the pressure gauge (1).
fig. 3:
Pos: 33 /Steuermodule ++++ Für alle Anleitungen ++++/++++++++ Seitenumbruch ++++++++ @ 1\mod_1452608869481_0.docx @ 22162 @ @ 1
Rev. 00 02/16
OptiAir CA12 Assembly / Connection 13
Pos: 34 /Kapitel/Bedienung / Betrieb/Equipment and Controls/Air Controls/Airmover-Luft einstellen-CA12 @ 1\mod_1461249063165_170.docx @ 27843 @ 2 @ 1
Setting the Airmover air The Airmover air is to be set, when a powder cloud rises over the powder surface and flows out through the powder hopper openings.
1. Set the Airmover air pressure on the pressure reducing valve (4) and monitor it on the pressure gauge (3).
2. Increase the pressure so far, until no more powder flows out of the powder hopper.
Notice
If these settings are once fixed, they can be left also when work interruptions take place. A reset of the adjusted values is thereby not necessary.
3. Switch on the OptiFlex A1 control system with the main switch
4. Set and/or operate the guns (see therefore the powder gun and gun control unit operating instructions)
Pos: 36 /Überschriften ++++ Für alle Anleitungen ++++/1. Ebene/Ersatzteilliste @ 1\mod_1452680828087_170.docx @ 22833 @ 1 @ 1
Rev. 00 02/16
14 Assembly / Connection OptiAir CA12
Rev. 00 02/16
OptiAir CA12 Spare parts list 15
Spare parts list
Pos: 37 /Kapitel/Ersatzteilliste/Bestellen von Ersatzteilen @ 1\mod_1456410477712_170.docx @ 27363 @ 2 @ 1
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 OptiGun GA03 automatic powder gun
Serial number 1234 5678
– Order no. 203 386, 1 piece, Clamp – Ø 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 using the spare parts from other manufacturers the explosion protection is no longer guaranteed. If any damage is caused by this use all guarantee claims become invalid!
– Only original Gema spare parts should be used!
Pos: 38 /Steuermodule ++++ Für alle Anleitungen ++++/++++++++ Seitenumbruch ++++++++ @ 1\mod_1452608869481_0.docx @ 22162 @ @ 1
Rev. 00 02/16
16 Spare parts list OptiAir CA12
Pos: 39 /Kapitel/Ersatzteilliste/Equipment and Controls/Air Controls/OptiAir CA12-A – Ersatzteilliste @ 1\mod_1461252532547_170.docx @ 27869 @ 2 @ 1
OptiAir CA12-A (for use with HF50/HF100 powder hopper) – spare parts list
OptiAir CA12-A Pneumatic-fluidizing unit – complete (without pos. 18) 1013 442
1 Elbow joint – 1/4", Ø 6 mm 265 691
2 Shuttle valve – 1/4" 259 217
5 Push button 1009 102
6 Connection sleeve – 1/4", Ø 6 mm 233 404
7 Pressure gauge – 0-6 bar, 1/8" 1003 300
8 Elbow joint – 1/8", Ø 6 mm 254 061
9 Pressure regulator – 0.1-4 bar, G1/4" 1009 101
10 Front frame – complete 1007 048
12 Adjusting elbow – Ø 6-4 mm 261 181
16 Adapter nipple – 3/8"-1/4" 202 550
17 Nut with kink protection for pos. 18 (not shown) 201 316
18 Plastic tube (Airmover air) – Ø 8/6 mm (not shown) 103 756*
# Wearing part
* Please indicate length Pos: 40 /Steuermodule ++++ Für alle Anleitungen ++++/++++++++ Seitenumbruch ++++++++ @ 1\mod_1452608869481_0.docx @ 22162 @ @ 1
Rev. 00 02/16
OptiAir CA12 Spare parts list 17
Pos: 41 /Kapitel/Ersatzteilliste/Equipment and Controls/Air Controls/OptiAir CA12-A – Ersatzteile @ 1\mod_1461253287920_170.docx @ 27896 @ 2 @ 1
OptiAir CA12-A (for use with HF50/HF100 powder hopper) – spare parts
fig. 4:
Pos: 42 /Steuermodule ++++ Für alle Anleitungen ++++/++++++++ Seitenumbruch ++++++++ @ 1\mod_1452608869481_0.docx @ 22162 @ @ 1
Rev. 00 02/16
18 Spare parts list OptiAir CA12
Pos: 43 /Kapitel/Ersatzteilliste/Equipment and Controls/Air Controls/OptiAir CA12-B – Ersatzteilliste @ 1\mod_1461253688736_170.docx @ 27949 @ 2 @ 1
OptiAir CA12-B (for use with HF150/HF200 powder hopper) – spare parts list
OptiAir CA12-B Pneumatic-fluidizing unit – complete (without pos. 18) 1013 443
1 Elbow joint – 1/4", Ø 6 mm 265 691
2 Shuttle valve – 1/4" 259 217
3 Sealing plug – 1/8" 258 687
4 Screw-in nipple – 3/8", Ø 8 mm 259 659
5 Push button 1009 102
6 Connection sleeve – 1/4", Ø 6 mm 233 404
7 Pressure gauge – 0-6 bar, 1/8" 1003 300
8 Elbow joint – 1/8", Ø 6 mm 254 061
9 Pressure regulator – 0.1-4 bar, G1/4" 1009 101
10 Front frame – complete 1007 048
11 Elbow joint – 3/8", Ø 8 mm 240 010
12 Adjusting elbow – Ø 6-4 mm 261 181
13 Pressure regulator – 3/8", remote controlled 244 384
14 Elbow joint – 1/8"-1/8" 235 733
15 Adapter nipple – 1/8"-1/4" 202 606
17 Nut with kink protection for pos. 18 (not shown) 201 316
18 Plastic tube (Airmover air) – Ø 8/6 mm (not shown) 103 756*
# Wearing part
* Please indicate length Pos: 44 /Steuermodule ++++ Für alle Anleitungen ++++/++++++++ Seitenumbruch ++++++++ @ 1\mod_1452608869481_0.docx @ 22162 @ @ 1
Rev. 00 02/16
OptiAir CA12 Spare parts list 19
Pos: 45 /Kapitel/Ersatzteilliste/Equipment and Controls/Air Controls/OptiAir CA12-B – Ersatzteile @ 1\mod_1461253688536_170.docx @ 27922 @ 2 @ 1
OptiAir CA12-B (for use with HF150/HF200 powder hopper) – spare parts
fig. 5:
=== Ende der Liste für Textmarke Inhalt ===
Rev. 00 02/16
OptiAir CA12 Index 21
Pos: 47 /Index ++++ Für alle Anleitungen ++++/Index @ 1\mod_1452682674446_170.docx @ 23053 @ @ 1
Index
A
About this instructions ........................................ 5 Assembly .......................................................... 11
C
Connection ....................................................... 11
D
Dimensions ........................................................ 9
F
Figure references in the text .............................. 6
I
Intended use ...................................................... 7
O
Operation ......................................................... 11
P
Pictograms ......................................................... 5 Pneumatic data .................................................. 9 Presentation of the contents .............................. 6 Product description ............................................ 9 Product specific security regulations ................. 7
S
Safety ................................................................. 7 Safety symbols .................................................. 5 Spare parts list ................................................. 15
T
Technical data ................................................... 9
=== Ende der Liste für Textmarke Index ===
Rev. 00
Pos: 49 /Rückseite ++++ Für alle Anleitungen ++++/Rückseite @ 1\mod_1452682695293_170.docx @ 23080 @ @ 1
=== Ende der Liste für Textmarke Rückseite ===
