E Operating Instructions and Spare Parts List 15
Copyright 2000 ITW Gema AG., CH-9015 St. Gall 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 ITW Gema AG. OptiTronic, OptiGun, EasyTronic, EasySelect, EasyFlow and SuperCorona are registered trademarks of ITW Gema AG. OptiMatic, OptiMove, OptiMaster, OptiPlus, OptiMulti and Gematic are trademarks of ITW Gema AG. 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. ITW Gema AG 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 ITW Gema AG Mövenstrasse 17 9015 St. Gallen Switzerland Tel.: +41 71 313 83 00 Fax: +41 71 313 83 83 E-Mail: info@itwgema.ch Internet: www.itwgema.ch 16
Table of Contents 1 Safety... 1 1.1 Personnel safety...1 1.2 Safety concept...1 1.3 Intended use...1 2 Product description... 2 2.1 Field of application...2 2.2 Function description...2 2.3 Technical data...3 2.4 Construction...4 2.4.1 Mechanical construction...4 2.4.2 Safety and monitoring devices...5 3 Mounting and assembly... 6 3.1 Place of installation and operation...6 4 Operation... 6 5. Spare Parts... 8 5.1 Ordering Spare Parts...8 5.2 List of spare parts (complete)...8 5.3 List of spare parts (Pneumatic cabinet)... 10 5.4 List of spare parts (PP02 Powder pump)... 12 5.5 List of spare parts (EP02 Powder pump)... 13 5.6 List of spare parts (Fluidizing / suction unit)... 14 17
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1 Safety 1.1 Personnel safety The tilting table may only be switched on and operated after careful reading of this manual. Incorrect operating of the tilting table can lead to personal injuries as well as damage to the table or other parts. The tilting table must be secured by the customer before start-up and during operation by providing fencing (see local regulations). Safety devices are not be dismantled, bypassed or ignored. Open covers hide the danger of injury. Safety devices must be kept in good working condition and not be allowed to be put out of action. Maintenance work on the tilting table may take place only when disconnected from the Mains. 1.2 Safety concept The tilting table is constituent part of the system and is thus integrated into the safety system of the overall system. Suitable measures must be taken for use outside of the safety concept. Only original ITW Gema spare parts may be used. Any warranty claim is void if damage occurs when using non-itw Gema parts. Only ITW Gema trained personnel may carry out repairs on the tilting table. 1.3 Intended use The tilting table is intended only for a defined range of application. Use outside of this area is considered as inapplicable use. 1
2 Product description 2.1 Field of application The tilting table serves to supply fresh powder from the manufacturer s container to the powder containers or powder guns. Powder conveying takes place via powder pumps with integrated powder fluidizing and distributing equipment. The tilting table can be subsequently integrated into any powder coating system. Fig. 2.1 FPS13 Tilting Table 2.2 Function description The powder container is placed directly onto the vibration table and vibrated by the motor mounted laterally on the table. For fluidizing the powder, in addition to table vibration, fluidizing air is fed into the exterior tube of the fluiding / suction unit, where it emerges at the lower end through the fluidizing pad. The area around the suction tube is thus fluidized, the powder receives fluid-like characteristics and is sucked into the tube. The table vibration causes a better flow of powder to the injectors and prevents accumulation of residual powder in the corners of the container. By tilting the large container up to 40 practically all the powder can be used up (optimal powder utilization). The vibration, and powder conveying only function if the level sensor in the main powder container indicates a shortage of powder. The vibrated and fluidized powder is sucked up by means of the conveying air through the suction tube into the powder pump and is transported further. 2
2.3 Technical data : Net weight: max. 550 kg Unladen weight: approx. 200 kg Motor voltage: 3 x 400 VAC Frequency: 50 Hz Compressed air connection max. input pressure: 10 bar Air requirement for tilting: < 1 Nm 3 /h Air requirement for pumps: see MB-064 Compressed air quality: max. water vapour content 1.3 g/m 3 max. oil vapour 0.1 mg/kg A separate control cabinet must be designated for the automatic control of the pumps. 3
2.4 Construction 2.4.1 Mechanical construction Depending on the version the tilting table can be equipped with 1-4 fluidizing / suction units. 4 1 3 2 5 6 7 9 8 10, 11, 12 Fig. 2.2 Layout of FPS13 Tilting Table 1 Powder pump 2 Fluidizing /suction unit 3 Fluidizing / suction unit holder 4 Clamping element 5 Pneumatic cabinet 6 Vibrator 7 Rubber damper 8 Steel bolt 9 Tilting stage 10 Base with cover plate 11 Tilting diaphragm (not shown) 12 Safety catch (not shown) 4
2.4.2 Safety and monitoring devices All moving axes must be secured before starting-up and during operation by fencing, provided by the customer (see local regulations). The tilting table is provided with an integrated, mechanical interlock for safety when a drop in pressure occurs. The tilting table, in the tilted position, can only be returned to the horizontal position by simultaneous pressing and holding the two stop push-buttons. 5
3 Mounting and assembly 3.1 Place of installation and operation After unpacking and installing the tilting table, it is to be fitted permanently to the floor with the steel bolts provided. Internal connections have already been made at the factory. Sufficient working space for loading and unloading the tilting table must be provided. 4 Operation 1. Move the fluidizing / suction unit(s) manually upward, lock the Retaining slide and place the large container on the tilting table. Fig. 4.1 Tilting Table with Fluidizing / suction unit - Raised position 2. Push the Retaining slide back and let the Fluidizing / suction unit(s) slowly downwards manually. Do not allow to drop down otherwise the Fluidizing pads can be damaged! Fig. 4.2 Tilting Table with Fluidizing / suction unit - Lowered position 6
3. Press the middle push-button(green). Note: The tilting table remains for the time being in its last position. It inclines automatically, as soon as the powder volume in the large container is reduced, until the maximum inclination of 40 is reached. Fig. 4.3 Start push-button for Tilting Table 4. If the large container empties - simultaniously press the two stop push-buttons (red ) and hold down until the tilting table is again in horizontal position. Fig. 4.4 Stop push-button for horizontal position 5. Lift the Fluidizing / suction unit(s) upward manually - change the large container and continue, starting from Point 2. 7
5. Spare Parts 5.1 Ordering Spare Parts To order spare parts for the tilting table we require the following specifications: Type of the tilting table Part number, quantity, and description of each spare part Example: Type: FPS13 Tilting table Order number: 363 910 Quantity: 1 piece Description: Clamping element - D40/D40 mm 5.2 List of spare parts (complete) The tilting table is provided with the following spare parts: 9 Pneumatics cabinet - compl. (see Section 5.3) 10 Clamping element - D40/D40 mm 363910 11 Pump holder - complete 390887 12 PP02 Powder pump - complete 357910 (see Section 5.4) EP02 Powder pump - complete (see Section 5.5) 13 Fluidizing / suction unit - complete 370843 (see Section 5.6) 20 Vibrator 258628 21 Gland 204919 22 Vibrator cable 103764 27 Foot clamping element 218472 28 Rubber damper 239232 51 Cheese head screw 239321 52 Hex. Screw - M8 X 30 mm 213950 53 Hex. Screw - M8 X 25 mm 244465 61 Shakeproof nut - M8 244449 70 Ribbed washer - M10 237981 71 Ribbed washer - M08 242870 80 Steel bolt - M10 X 90 mm 245216 8
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5.3 List of spare parts (Pneumatic cabinet) 1 Control cabinet 390852 2 Distributor tube 373427 3 Mounting bracket 363740 4 Connector retainer 390747 5 Support profile 345245 6 Valve - D1.9 mm 372900 7 Valve cable - L=0.7m 373605 10 Lead-through 202967 11 Elbow 252867 12 Hose connector 223069 13 T-piece 223301 14 Pressure control valve 243710 15 Pressure gauge - 0-10bar 243620 16 Panel nut 259519 17 Mounting bracket 212024 18 Elbow 223166 19 Adapter 252875 20 Plug 258679 22 Divided double nipple 243582 23 Single solenoid valve 259500 24 Adapter 202622 25 Female hose connector 223050 26 Quick coupling 239267 27 Double nipple 202738 28 Inline regulator - 4 bar 265292 29 Pressure control valve - 0-4 bar 240028 30 Pressure gauge - 0-4 bar 235814 31 Adapter 223778 32 Elbow 253863 33 Single piloted valve 253944 34 Elbow 251372 35 Silencer 251305 36 Elbow 237604 37 Divided double nipple 253847 38 Adapter 202649 39 T-piece 246727 40 Coupling sleeve 236020 41 Double nipple 242209 42 OR valve 259217 43 Elbow 265691 44 T-piece 239780 45 Setting angle 237990 46 Y-plug connection 264814 47 Lead-through 253880 48 Lead-through 250848 49 Valve +carrier plate 260746 50 Push-button - red 203491 51 Push-button - green 203483 10
52 Elbow 261181 53 Pressure indicator - green 265705 60 Solaflex hose 102296 61 Solaflex hose 100498 63 Plastic tube 103756 64 Plastic tube 103144 66 Hose clamp 226335 67 Hose clamp 203386 70 Gland 204366 71 2 connection terminal clamp 2.5 mm 2 P 240273 72 2 connection terminal clamp - 2.5 mm 2 N 240281 73 2 connection terminal clamp - 2.5 mm 2 PE 240117 74 2 connection terminal end plate 238945 75 2 connection terminal end clamp - 2.5 mm 2 238368 80 Hex. Shakeproof screw - M6 x 12 mm 244406 81 Cheese head screw M5 x 65 mm 244759 82 Screw - M5 x 12 mm - Eco-Fix 239941 90 Clip nut M06 204307 91 Clip nut M05 238201 92 Nut - M5 mm 205150 93 Cap nut - M5 mm 205044 94 Nut - M5 mm 243892 11
5.4 List of spare parts (PP02 Powder pump) 1 Non-return valve 347,345 2 Nozzle 357,936 3 Injector housing 357,928 4 Tube coupling 357 944# 6 Quick coupling 239,267 7 Hose clamp 203,386 8 Conveying air hose - NW 10 100 498* 9 Powder hose - NW 22 103 780*# # Wear part * Please indicate length. 1 2 3 4 9 6 7 8 12
5.5 List of spare parts (EP02 Powder pump) 1 Non-return valve 347,345 2 EP02 Nozzle 387,967 3 Pump housing 387,959 4 Hose coupling 388 009# 5 Sleeve 388,017 6 Quick coupling 239,267 7 Hose clamp 203,386 8 Conveying air hose - NW 10 100 498* 9 Powder hose - NW 22 103 780*# # Wear part * Please indicate length. 1 2 3 4, 5 9 6 7 8 13
5.6 List of spare parts (Fluidizing / suction unit) PP02: Fluidizing / suction unit - complete (without Powder pump) 370 843 1 O-ring - D25 x 2 mm 241 733# 2 O-ring - D35 x 2 mm 220 442# 3 Fluidizing pad 237 264# # Wear part 1 2 3 14