Gema OptiFlow IG06-BN Guide

Rev. 00 1017 573 EN
Operating instructions and Spare parts list
Powder injector
OptiFlow IG06-BN
This product was developed for use with electrically non-
conducting powders. The use of electrically conducting powders
(like metallic or graphite powders) can cause a permanent
decrease of functioning.
Translation of the original operating instructions

Rev. 00 05/19
Documentation OptiFlow IG06-BN
© Copyright 2019 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.
Gema, EquiFlow, MagicCompact, MagicCylinder, OptiCenter, OptiFlex,
OptiGun, OptiSelect and OptiStar are registered trademarks of Gema
Switzerland GmbH.
ClassicLine, ClassicStandard, ClassicOpen, DVC (Digital Valve Control),
GemaConnect, MagicControl, MagicPlus, MonoCyclone, MRS,
MultiColor, MultiStar, OptiAir, OptiControl, OptiColor, OptiFeed, OptiFlow,
OptiHopper, OptiMove, OptiSieve, OptiSpeeder, OptiSpray, PCC (Precise
Charge Control), RobotGun, SIT (Smart Inline Technology) und
SuperCorona 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:[phone]
Fax.: [phone]
E-mail: [email protected]

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OptiFlow IG06-BN Table of contents
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3
Table of contents
About these instructions 5
General information ................................................................................................5
Keeping the Manual................................................................................................5
Safety symbols (pictograms)...................................................................................5
Structure of Safety Notes...........................................................................6
Presentation of the contents...................................................................................6
Figure references in the text......................................................................6
Safety 7
General information ................................................................................................7
Basic safety instructions .........................................................................................7
Product specific security regulations ......................................................................8
Product description 9
Intended use ...........................................................................................................9
Reasonably foreseeable misuse................................................................9
Typical properties –characteristics of the functions.............................................10
Structure................................................................................................................10
Overall view..............................................................................................10
Principle of the injector..........................................................................................11
Maintenance / Repairs 13
Cleaning................................................................................................................13
Cleaning the injector.............................................................................................13
Cleaning the check valve units.............................................................................14
Replacing the insert sleeve...................................................................................15
Fault clearance 17
Faults ....................................................................................................................17
Disposal 19
Introduction ...........................................................................................................19
Requirements on personnel carrying out the work..................................19
Disposal regulations.................................................................................19
Materials...................................................................................................19
Spare parts list 21
Ordering spare parts.............................................................................................21
OptiFlow IG06-BN –spare parts list .....................................................................22
OptiFlow IG06 –spare parts.................................................................................23

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OptiFlow IG06-BN About these instructions
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5
About these instructions
General information
This operating manual contains all important information which you
require for the working with the OptiFlow IG06-BN. It will safely guide you
through the start-up process and give you references and tips for the
optimal use when working with your powder coating system.
Information about the functional mode of the individual system
components should be referenced in the respective enclosed documents.
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 Gema
instructions. The general safety precautions must also be followed as well
as the regulations in the relevant 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.
ATTENTION
Indicates a potentially harmful situation. If not avoided, the equipment or
something in its surrounding may be damaged.

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About these instructions OptiFlow IG06-BN
ENVIRONMENT
Indicates a potentially harmful situation which, if not avoided, may have
harmful consequences 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 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."

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OptiFlow IG06-BN Safety
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7
Safety
General information
This chapter provides the user and third parties who operate this product
with all essential safety regulations, the adherence to which is imperative.
These safety regulations must be read and understood in their entirety
before the product is put into operation.
The standards and guidelines applied during the development,
manufacture and configuration are described in the EC declaration of
conformity and in the manufacturer’s declaration.
WARNING
Working without instructions
Working without instructions or with individual pages from the
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.
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. 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.
–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.

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
Safety OptiFlow IG06-BN
–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.
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.
–It must be ensured, that all components are earthed according to the
local regulations before start-up.
For further security information, see the more detailed Gema
safety regulations!

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OptiFlow IG06-BN Product description

9
Product description
Intended use
The OptiFlow injector is used to convey powders containing Boron Nitride
between the powder hopper and the powder gun.
fig.
1
: Powder injector with coded quick release connections
Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of the intended 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 not considered as intended use. The manufacturer is not
responsible for any incorrect use and the risks associated with such
actions are assumed by the user alone!
Reasonably foreseeable misuse
–Use of metallic, graphite or enamel powder
–Use with insufficient compressed air quality
–Use of moist powder
–Incorrectly assembled individual parts

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
Product description OptiFlow IG06-BN
Typical properties –characteristics of the functions
The OptiFlow Injector is a plug-in type and permits easy handling and
quick cleaning. All connections are plug-in types and not interchangeable.
The injector can be disassembled without special tools.
The injector is supplied with a PTFE insert sleeve as standard.
Structure
Overall view
fig.
2
1 Check valve unit
(supplementary air)
2 Powder hose quick release
connection
3 Powder hopper connection
4 Injector housing
6 Check valve unit
(conveying air)

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OptiFlow IG06-BN Product description
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11
Principle of the injector
When air flows through a nozzle into a cavity with an attached outlet in
the continuation of the airflow, a vacuum will be created in the cavity (see
figure below). This effect is used now for aspirating powder through a
suction opening –a powder/air mixture will be created.
fig.
3
1 Conveying air
2 Supplementary air
3 Insert sleeve
4 Powder/air mixture
5 Vacuum
6 Suction tube
7 fluidized powder
8 Powder container
9 Nozzle
This powder/air mixture is fed through to the powder hose to the gun. The
concentration of the powder/air mixture and therefore the powder output
amount, depends on the conveying and supplementary air volume, the
powder quality, the powder hose length, the powder hose diameter, the
number of coils in the hose, the height difference between the powder
gun and the injector and the nozzle type. Place great importance on the
insert sleeve condition, because wear causes the powder output to
reduce drastically.
Experience with pneumatic material handling technology shows that
pneumatic transport of fine solid matter (powder) in the form of tubing
(hose), the transporting medium requires a certain volume of air per unit
of time. If a hose diameter of 11 mm is used, the value is approx. 4 m³/h.
In order to reduce the powder output, the vacuum in the cavity of the
injector must be lowered by reducing the conveying air pressure. By
reducing the conveying air pressure, the air volume in the powder hose
sinks to below the optimum value of 4 m³/h, the powder transport
becomes irregular and the so-called "pumping" takes place. In order to
prevent this from happening, supplementary air is added until the total air
volume in the powder hose is 4-5 m³/h once more. This takes place fully
automatically by the Gema control unit.

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Product description OptiFlow IG06-BN

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OptiFlow IG06-BN Maintenance / Repairs
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13
Maintenance / Repairs
Reinigung
Cleaning
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!
Cleaning the injector
1. Remove the injector
2. Remove the powder hose from the hose connection (2)
3. Clean the hose connection (2) with compressed air which is free of
oil and water, and check for wear
4. Clean the injector body (4) with compressed air which is free of oil
and water.
–Any contamination can be seen through the opening of the
hopper fitting (3)
5. If the injector is severely fouled, it must be dismantled
ATTENTION
Injector parts may be damaged during the cleaning process.
►Remove the check valve units (1 and 6) with the correct sized
spanner.
►Clean the component parts with compressed air and, if
necessary, dissolve sintered deposits with nitro-thinner.
►Do not use acetone, do not scrape!
6. Reinsert the injector and fix it

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Maintenance / Repairs OptiFlow IG06-BN
fig.
4
1 Check valve unit
(supplementary air)
2 Powder hose quick release
connection
3 Powder hopper connection
4 Injector housing
6 Check valve unit
(conveying air)
Cleaning the check valve units
ATTENTION
Parts of the check valve unit may be damaged during the
dismantling process.
►Blow off the filter elements from the inside to the outside!
►Do not immerse the filter elements in fluidities or solvents
fig.
5
1 Connection/plug
2 O-ring
3 Filter element

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OptiFlow IG06-BN Maintenance / Repairs
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15
Replacing the insert sleeve
1.
2.
3.
4.

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Maintenance / Repairs OptiFlow IG06-BN

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OptiFlow IG06-BN Fault clearance
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17
Fault clearance
Faults The following lists possible faults during operation and their clearance.
Fault
Cause
Corrective action
The gun does not
spray powder
although the
control unit is
switched on
Injector nozzle,
check valve unit,
powder hose or
powder gun are
clogged
Clean the
corresponding parts
and if necessary,
replace them
Gun achieving only
poor spray profile
Conveying vacuum
too low
Increase the powder
quantity and/or total
air volume on the
control unit
Insert sleeve worn,
not or incorrect
inserted
Replace or install the
insert sleeve.
Observe the indexing
cam!
Insert sleeve is
worn after a short
operating duration
Clean the nozzle, if
damaged, replace it

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Fault clearance OptiFlow IG06-BN

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OptiFlow IG06-BN Disposal
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Disposal
Introduction
Requirements on personnel carrying out the
work
The disposal of the product is to be carried out by the owner or operator.
When disposing of components that are not manufactured 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 and taken to
the appropriate collection points.

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Disposal OptiFlow IG06-BN