Gema OptiFlow IG07-P User manual

Rev. 00 1011 536 EN
Operating instructions and Spare parts list
Powder injector
OptiFlow IG07-P
Translation of the original operating instructions

Rev. 00 02/19
Documentation OptiFlow IG07-P
© 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]

Rev. 00 02/19
OptiFlow IG07-P Table of contents

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..............................................................10
Typical characteristics –properties of the functions.............................................10
Structure................................................................................................................10
Overall view..............................................................................................10
Principle of the injector..........................................................................................11
Powder volume setting for OptiFlow Injector........................................................12
Powder output (reference values)............................................................12
Available accessories ...........................................................................................13
Maintenance / Repairs 15
Cleaning................................................................................................................15
Cleaning the injector.............................................................................................15
Cleaning the check valve units.............................................................................17
Changing the cartridge..........................................................................................18
Fault clearance 19
Faults ....................................................................................................................19
Disposal 21
Introduction ...........................................................................................................21
Requirements on personnel carrying out the work..................................21
Disposal regulations.................................................................................21
Materials...................................................................................................21
Spare parts list 23
Ordering spare parts.............................................................................................23
OptiFlow IG07-P –Spare parts list.......................................................................24
OptiFlow IG07-P –spare parts .............................................................................25

Rev. 00 02/19
4

Table of contents OptiFlow IG07-P

Rev. 00 02/19
OptiFlow IG07-P About these instructions

5
About these instructions
General information
This operating manual contains all important information which you
require for the working with the OptiFlow IG07-P. 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.

Rev. 00 02/19
6

About these instructions OptiFlow IG07-P
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."

Rev. 00 02/19
OptiFlow IG07-P Safety

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.

Rev. 00 02/19
8

Safety OptiFlow IG07-P
–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!

Rev. 00 02/19
OptiFlow IG07-P Product description

9
Product description
Intended use
The OptiFlow injector is used for conveying normal organic powders
between the powder management center and the powder gun.
fig.
1
: Powder injector with coded quick release connections
The injector is certified for using in the following zone, if powder hoses
with conductive strips are used, and the grounding resistance is less
than 1 MOhm!
Explosion protection
Zone
II 3 D
22
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.
Any other use is considered non-compliant. The manufacturer is not
responsible for any incorrect use and the risks associated with such
actions are assumed by the user alone!

Rev. 00 02/19
10

Product description OptiFlow IG07-P
Reasonably foreseeable misuse
–Use of enameled powder
–Use with insufficient compressed air quality
–Use of moist powder
–Incorrectly assembled individual parts
Typical characteristics –properties 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 equipped with an additional connection for the powder
hose rinsing.
The injector is supplied with a PTFE / ETFE cartridge 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
5 Release trigger
6 Check valve unit
(conveying air)
7 Powder hose rinsing
connection

Rev. 00 02/19
OptiFlow IG07-P Product description

11
Principle of the injector
When air flows through a nozzle into a cavity, 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 passes through the nozzle into the insert sleeve and through the
powder hose into the gun.
The powder output volume depends on the ratio between the conveying
and additional air:
–The conveying air creates the intake depression.
–The additional air influences the flow velocity.
–The total air is the sum of the conveying and additional air.
The transport of fine solids such as powder requires a certain air volume
per time unit to facilitate airborne conveyance. If a hose diameter of
11 mm is used, the value is approx. 4 Nm³/h.
If the powder transport becomes irregular, the so-called "pumping" takes
place.

Rev. 00 02/19
12

Product description OptiFlow IG07-P
In order to prevent this from happening, supplementary air is added until
the volume of the air in the powder hose is sufficient available once more.
The conveying quality depends on the quality of the powder, the powder
hose length, the hose diameter and the number of hose curvatures. Place
great importance on the insert sleeve condition, because clogging or
sintering causes the powder output to reduce drastically.
Powder volume setting for OptiFlow Injector
In order to set the ideal powder volume on the OptiStar gun control unit, it
is recommended to select the firmness of the powder cloud or the total air
first. As guide values for different powder hoses, the following can be
assumed:
–Powder hose 74 type, Ø 10 mm, 3-5 m³/h
–Powder hose 66 type, Ø 11 mm, 4-5 m³/h
According to the prevailing conditions (powder, powder hose layout, the
parts to be coated) a low to lowest total air can also be set with the
standard hose 74 type, Ø 10 mm.
If a very large powder output is required, it is recommended to select a
larger powder hose internal diameter (Ø 12 mm).
It should to be noted, that if irregular or pumping conveying
occurs, as a rule, the total air is set too low!
Powder output (reference values)
General conditions for the OptiFlow Injector
Powder type
Epoxy/polyester
Powder hose Ø (mm)
11
Type of powder hose
POE with guide strips
Input pressure OptiStar (bar)
5.5
Correction value C0
Powder output zeroing
adjustment

Rev. 00 02/19
OptiFlow IG07-P Product description

13
Guide values for OptiStar with OptiFlow Injector
All values in these tables are guide values for new nozzle inserts.
Differing environmental conditions, wear and different powder types can
affect the table values.
Hose internal diameter (mm)
Ø 11
Hose length (m)
6
12
18
Total air volume (Nm³/h)
3.5
5.5
3.5
5.5
3.5
5.5
Powder output (g/min)
Powder output (%)
20
90
105
65
75
45
60
40
170
205
135
150
100
120
60
235
280
185
215
145
170
80
290
350
235
270
185
220
100
340
405
280
320
220
260
Available accessories
–Multi-Tool / Plug gauge for checking wear (order no. 1017 201)

Rev. 00 02/19
14

Product description OptiFlow IG07-P

Rev. 00 02/19
OptiFlow IG07-P Maintenance / Repairs

15
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
ATTENTION
Injector parts may be damaged during the cleaning process.
►Clean the component parts with compressed air and, if
necessary, dissolve sintered deposits with nitro-thinner.
►Do not use acetone, do not scrape!
Cleaning intensity depends of the powder used. For optimal cleaning
results, we recommend dismantling the entire injector into its dismantable
components.
1. Remove the injector
2. Remove the powder hose from the hose connection
3. Clean the hose connection with compressed air which is free of oil
and water, and check for wear
4. Clean the injector body with compressed air which is free of oil and
water.
–Any contamination can be seen through the opening of the
hopper fitting
5. If the injector is severely fouled, it must be dismantled

Rev. 00 02/19
16

Maintenance / Repairs OptiFlow IG07-P
ATTENTION
Individual parts may be damaged during the cleaning process.
►Please dismantle carefully to avoid damages!
►Remove the check valve units (1 and 6) with the correct sized
spanner.
6. Reinsert the injector and fix it
fig.
4
1 Check valve unit
(supplementary air)
2 Powder hose quick release
connection
3 Powder hopper connection
4 Injector housing
5 Release trigger
6 Check valve unit
(conveying air)
7 Powder hose rinsing
connection

Rev. 00 02/19
OptiFlow IG07-P Maintenance / Repairs

17
Cleaning the check valve units
ATTENTION
Damage or loss of function!
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!
►Never remove the supporting ring!
fig.
5
1 Connection/plug
2 O-ring
3 Filter element
3.1 Supporting ring

Rev. 00 02/19
18

Maintenance / Repairs OptiFlow IG07-P
Changing the cartridge
The wear of the cartridge should be checked with the appropriate plug
gauge prior to replacement (Order no. 1017 201).
1.
2.
3.
4.
5.
6.
7.
8.

Rev. 00 02/19
OptiFlow IG07-P Fault clearance

19
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
Cartridge worn,
clogged or not
inserted
Replace or install the
cartridge.

Rev. 00 02/19
20

Fault clearance OptiFlow IG07-P