OptiMatic 2 Automatic Powder System (AS02)

Transcription

1 E Operating Instructions and Spare Parts List Automatic Powder System (AS0) Translation of the original operating instructions

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3 Table of Contents. Fields of application.... Scope of delivery.... Designation.... General information.... Mains supply.... Compressed air Setting up the OptiMatic- Automatic Powder System Possibilities Assembly instructions OptiTronic Control CG0 Power Supply Electrical diagrams Block diagram: OptiTronic Control System without CANBus Digital Connector CD0: Connections X-X Block diagram - Power Main Board for OptiTronic Control unit CG Spare Parts List Ordering Spare Parts OptiMatic- - Switch Cabinet Pressure regulator/filter unit Power Main Board CD 0 DigitalConnector : Grounding connection... 5 Issued /0 9

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5 . Fields of application The automatic powder system with Gema automatic powder guns is especially designed to meet the demands of production line applications in both manufacturing, and custom electrostatic coating installations, where reliability in automated working, comfortable operation, and safety are the outstanding advantages to the user. The flexible, modular structure of the is readily adaptable to any changes in your installation. Interlocking OptiMaster Gematic OptiTronic OptiTronic OptiTronic OptiTronic OptiTronic OptiTronic OptiPlus-C OptiPlus-P OptiPlus-A Control modules Powder hopper Reciprocator Guns with level sensor Fig.. Scope of delivery The scope of delivery depends on the number and composition of the modules (see above). It is extremely important to follow the "assembly instructions" in this manual, and the operating instructions supplied with every control unit, when setting up and operating the System. Issued /0

6 . Designation OptiMatic- Issued /0 Powder hoppers Injectors Controls Atomizer OptiGun A(X) OptiGun AE Enamel PG -A(X) PG -AE Enamel OptiMaster Powder Master Control (CM0 / 0) (for fluidized powder hoppers) OptiTronic Gematic OptiPlus-A OptiPlus-C OptiPlus-C OptiPlus-P OptiFlow PI -V PI -H PI -V EI -V EI -H PH - PH 50-//8 PH 00- PH 50- PH 00- Powder Gun Control (CG0) Powder Reciprocator Control (CR0) Pneumatic / Fluidizing Unit (CA0) Hose Rinsing Control (CC0) (Individual rinsing) Hose Rinsing Control (CC0) (Group rinsing) Fresh Powder Control (CP0) Powder Injector (IG0) Powder Injector - Vertical connections Powder Injector - Horizontal connections Powder Injector - Vertical connections with a rinsing air connection Enamel Injector - Vertical connections Enamel Injector - Horizontal connections Number of injectors Capacity in litres

7 . General information. Mains supply This is general information, for more detailed information see corresponding Operating Instructions. Compressed air - The Mains supply is the local voltage. See also Wiring diagram - The mains frequency can be 50 or 60 Hz. - Adding the connected load of the individual units together gives the total connected load for the complete system. - All electrical components correspond to the IP 5 type of protection. - The equipment only requires a compressed air supply on the main compressed air network (Main air input and compressed air distributor) - An OptiPlusA unit is always fitted to monitor the fluidizating air. - The following values for compressed air must be maintained : Input pressure : 6-0 bar Max. water vapour :. g/m Max. oil vapour : 0. mg/kg IMPORTANT For a faultless functioning of the OptiTronic Control units CG0 the main compressed air input pressure must be set at exactly 5.0 bar. Pressure regulator/filter unit is placed at the rear of the control cabinet. Issued /0

8 5. Setting up the OptiMatic- Automatic Powder System Compressed air input Main valve Air distributor min Front view Free space for access to the control cabinet Side view Fig. 5. Possibilities - Up to control module units can be fitted. - cabinets can only be mounted side by side (without a gap) or with one side against a wall. - Openings which are not used should be sealed with a coverplate. When the system is extended the coverplate can easily be unscrewed. Issued /0

9 5. Assembly instructions - After unpacking and assembling the System the control cabinet must be fitted to the floor with the steel bolts supplied. The fixing holes are found in the base at the rear of the cabinet. - Internal connections have already been made at the factory, connections to control units of external plant must, however, be made before starting up. The connection possibilities for individual control units are found in the accompanying operating instructions. - When connecting the pneumatic hoses in the control cabinet their lengths, and radii should be specially taken into account! 5. OptiTronic Control CG0 Power Supply NOTICE OptiTronic Control CG0 may only be connected to a VDC power supply. The OptiTronic Control units are only suitable for power supplied from a special Power Main Board. The Power Main Board can be fitted with a maximum of power modules ( power module per OptiTronic). When retrofitting the equipment with each OptiTronic Control unit a further Power module has to be ordered, which can be easily inserted onto the Power Main Board. Issued /0 5

10 6. Electrical diagrams 6. Block diagram: OptiTronic Control System without CANBus DIGITAL CONNECTOR CD0* 885 POWER MAINBOARD VA TRAFO. (.). (SL). (DB).. (.). (SL). (DB). X AC9 - AC X-GUN X-GUN X-GUN X AC5 - AC8 X AC - AC X-GUN OPTI TRONIC OPTI TRONIC GUN GUN SYSTEM LOCK* SYSTEM LOCK* DIGITAL BUS* GUN GUN GUN GUN X X X X X5 Supply Data Res. OUT Res. IN Adres Error Remote Strobe System OPTI TRONIC AC IN. (.). (SL). (DB).. (.). (SL). (DB). DIGITAL BUS* DIGITAL BUS* DIGITAL BUS* GUN SYSTEM LOCK* x Power Modul 8686 * OPTION OPTI TRONIC GUN SYSTEM LOCK* 00V : 895 5V : V: 898 0V : V : 887 Issued /0 Fig. 6

11 6. Digital Connector CD0: Connections X-X5 V GND X X D0 D D D D D5 D6 D7 A0 A A DataBus - Bit 8 Bit Desired value Bit ID No. X ResO_0 Err_0 ResO_0 Err_0 ResO_0 Err_0 ResO_0 Err_0 ResO_05 Err_05 ResO_06 Err_06 ResO_07 Err_07 ResO_08 Err_08 ResO_09 Err_09 ResO_0 Err_0 ResO_ Err_ ResO_ Err_ - Guns Collective error message X Res_0 Rem_0 Res_0 Rem_0 Res_0 Rem_0 Res_0 Rem_0 Res_05 Rem_05 Res_06 Rem_06 Res_07 Rem_07 Res_08 Rem_08 Res_09 Rem_09 Res_0 Rem_0 Res_ Rem_ Res_ Rem_ - Guns Remote / Manual X Strob_0 Sys_0 Strob_0 Sys_0 Strob_0 Sys_0 Strob_0 Sys_0 Strob_05 Sys_05 Strob_06 Sys_06 Strob_07 Sys_07 Strob_08 Sys_08 Strob_09 Sys_09 Strob_0 Sys_0 Strob_ Sys_ Strob_ Sys_ - Guns System ON / OFF Strobe Fig. V DC External Supply for all Digital In / Outputs Issued /0 7

12 6. Block diagram - Power Main Board for OptiTronic Control unit CG0 Issued /0 POWER MODUL NR X-GUN X POWER MAINBOARD NR Fig. 5 POWER MODUL NR POWER MODUL NR POWER MODUL NR SYS_ GD_ V_ PE SYS_ GD_ V_ PE SYS_ GD_ V_ PE SYS_ GD_ V_ PE X X SYSTEM SYSTEM SYSTEM SYSTEM SYSTEM 5 SYSTEM 6 SYSTEM 7 SYSTEM 8 SYSTEM 9 SYSTEM SYSTEM SYSTEM X X5 GND PE TRANSFORMATOR 00VA SPEISUNG 0 V 00/5/00 V 0/00 V PE PE X-GUN X-GUN X-GUN 8

13 7. Spare Parts List 7. 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 : OptiMatic- Serial no : XXXX XXXX. Order no : 65 piece, Sealing gasket When ordering cable or hose material the length required must also be given. The spare part numbers of this yard/metre ware is always marked with an *. The spare part number of yard/metre ware always begins with All wear parts are marked with a #. All dimensions of plastic hoses are given as external and internal diameters : e.g. ø 8 / 6 mm = 8 mm outside diameter (o/d) / 6 mm inside diameter (I/d). Issued /0 9

14 7. OptiMatic- - Switch Cabinet Drawer holder - large (left) Roller guide (left) 0 Escutcheon plate - small 99 Door lock Key (for items and 9) Drawer holder - large (right) Roller guide (right) Door lock Rear wall panel 606 Stud Pressure regulator/filter unit -complete (see also page ) Double adapter - /" 70 7 Clamp nut - /" Solenoid valve - VAC 6 Solenoid valve - VDC on request Solenoid valve - 0 VAC Solenoid valve - 0 VAC on request 9 Double adapter - /" Distributor block - 0x ø 8 mm 50 Air connection ring - /8" 970 Double adapter - /8" 00 Cap nut - /8" 0 57 Hose nipple - ø 0 mm Solaflex hose - ø 6 / 0 mm 00 98* 6 Hose clamp ring Air connection adapter - /8" Air connection ring - ø 8 mm Air connection adapter - /8" 00 0 Plug - ø 8 mm 8 0 Plug screw 0 9 Cover plate - for large drawer unit Floor plate - for large drawer unit Front plate - large Drawer holder - small (left) Drawer holder - small (right) 07 0 Mounting plate - empty 5 90 Mounting plate - empty Mounting plate - empty 6 76 Issued 0/05 * Indicate length required For electrical components see accompanying wiring diagram 0

15 OptiMatic- - Switch Cabinet 5; 9 ; 7; 8 5; 6; ; Fig. 6 Issued /0

16 7. Pressure regulator/filter unit Pressure regulator / Filter unit - complete 87 Filter unit - G/ 69 Pressure regulator bar 695 Pressure gauge - /8"a bar 5979 Adapter - /"i -/"i 06 5 Adapter - /8"i -/"a 9 6 Double nipple - /"a -/"a 50 7 Double nipple - /"a -/"a detachable 58 8 Double nipple - /"a x50 mm Adapter - /"a -/"i 66 0 Adapter - /"i-/"i 5867 Hose connection - D7.0 mm-/"a 069 Plug screw - /"a X 8 7 View X Ansicht X 0 5 ; 9 6 Issued /0 Fig. 7

17 7. Power Main Board Power Main Board - for guns Power Module - x per gun Transformer - 00 VA (prim. 00 V) for guns 8 95 Transformer - 00 VA (prim. 5 V) for guns Transformer - 00 VA (prim. 00 V) for guns 8 98 Transformer - 00 VA (prim. 0 V) for guns 8 86 Transformer - 00 VA (prim. 00 V) for guns 8 87 OptiTronic CG 0 Power supply cable - 5m OptiTronic CG 0 Power supply cable - 0m Fig. 8 Issued /0

18 7.5 CD0 DigitalConnector CD0 Digital Connector - for guns 8 85 Digital cable - 9 pin -.5 m Digital cable - 9 pin m Digital cable - 9 pin m Issued /0 Fig. 9

19 7.6 : Grounding connection Studding - M6x50 mm Nut Washer - M Shakeproof washer 00 50# 8 Grounding cable Milled nut Rear view # Wear Part Fig. 0 Issued /0 5

20 Documentation OptiMatic Copyright 000 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. OptiTronic, OptiGun, EasyTronic, EasySelect, EasyFlow and SuperCorona are registered trademarks of Gema Switzerland GmbH. OptiMatic, OptiMove, OptiMaster, OptiPlus, OptiMulti and Gematic 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 endeavoured 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 issue. 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. Printed in Switzerland Gema Switzerland GmbH Mövenstrasse St.Gallen Switzerland Phone: Fax: info@gema.eu.com Internet: Issued /0 6