Gema OptiFlex A1 Guide

Rev. 00 1011 538 EN
Operating instructions and Spare parts list
Control system
OptiFlex A1 (AS07)
Translation of the original operating instructions

Rev. 00 05/23
Documentation OptiFlex A1 (AS07)
© Copyright 2017 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, OptiStar, OptiStar All-in-One and PowerBoost 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) and
SuperCorona are registered 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
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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 information regarding patents, see
www.gemapowdercoating.com/patents or
www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone: [phone]
Email: [email protected]

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OptiFlex A1 (AS07) 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
Basic safety instructions .........................................................................................7
Product specific security regulations ......................................................................8
Product description 9
Intended use ...........................................................................................................9
Reasonably foreseeable misuse...........................................................................10
Technical Data......................................................................................................10
Electrical data ..........................................................................................10
Pneumatic data........................................................................................10
Dimensions ..............................................................................................10
Sound pressure level...............................................................................11
Design and function..............................................................................................12
Overall view..............................................................................................12
System components ................................................................................12
Available accessories ..............................................................................14
Possible system configurations ...............................................................14
Scope of delivery ..................................................................................................15
Typical properties –characteristics of the functions.............................................15
Assembly / Connection 17
Assembly notes........................................................................................17
OptiFlex A1 Control cabinet.....................................................................18
Connection instructions.........................................................................................19
Start-up 21
Preparation for start-up.........................................................................................21
Basic conditions.......................................................................................21
General information .................................................................................21
Compressed air........................................................................................21
Power supply............................................................................................21
Maintenance / Repairs 23
General information ..............................................................................................23
Periodic checks.....................................................................................................23
Repair work...........................................................................................................23

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Table of contents OptiFlex A1 (AS07)
Decommissioning / Storage 25
Shutdown..............................................................................................................25
If in disuse for several days.....................................................................25
Storage conditions................................................................................................25
Hazard notes...........................................................................................25
Type of storage........................................................................................25
Storage duration......................................................................................25
Space requirements ................................................................................25
Physical requirements.............................................................................26
Maintenance during storage.................................................................................26
Maintenance schedule.............................................................................26
Maintenance works..................................................................................26
Disposal 27
Introduction...........................................................................................................27
Requirements on personnel carrying out the work..................................27
Disposal regulations................................................................................27
Materials..................................................................................................27
Disassembly of component groups......................................................................27
Spare parts list 29
Ordering spare parts.............................................................................................29
OptiFlex A1 control cabinet –spare parts list.......................................................30
Control cabinet –spare parts ...............................................................................31
Pneumatic group AS07 –spare parts list.............................................................32
Pneumatic group AS07-CG10 –spare parts list ..................................................34

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OptiFlex A1 (AS07) About these instructions
•
5
About these instructions
General information
This operating manual contains all the important information which you
require for the working with the OptiFlex A1 (AS07). 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 OptiFlex A1 (AS07)
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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OptiFlex A1 (AS07) Safety
•
7
Safety
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.
–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.

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Safety OptiFlex A1 (AS07)
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!
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.

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OptiFlex A1 (AS07) Product description
•
9
Product description
Intended use
This control system is designed exclusively for the incorporation of the
following components:
–Control units for powder coating guns and injectors
–Control units for moving axes
–Control units for fluidizing/venting processes
–Electrical interlockings (plant safety system)
Fig.
1
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!

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Product description OptiFlex A1 (AS07)
For a better understanding of the interrelationships in powder coating, it is
recommended that the operating instructions for all other components be
read as well, so as to be familiar with their functions too.
Reasonably foreseeable misuse
–Operation without the proper training
–Use in connection with unauthorized coating devices or components
Technical Data
Electrical data
OptiFlex A1 (AS07)
Main input voltage
100-240 VAC
Device input voltage
100-240 VAC
(for gun control units)
200-240 VAC
(for axis control units)
Frequency
50/60 Hz
Input power (sum of the power
values of all control units)
40 VA per gun control unit
1.1 VA per axis control unit
Protection type (control units)
IP54
Temperature range (operation)
10-40 °C / 50-104 °F
Approvals
Certified for use in ATEX - zone 22
Pneumatic data
OptiFlex A1 (AS07)
Min. input pressure
6 bar / 87 psi
Max. input pressure
8 bar / 116 psi
Max. water vapor content of the
compressed air
1.3 g/m³ –ISO 8573-1 Class 3-4
Max. oil vapor content of the
compressed air (oil/water)
0.1 mg/m³ –ISO 8573-1 Class 2
Total air consumption
8 Nm³/h per gun (plus powder
hopper air requirement)
Dimensions
OptiFlex A1 (AS07)
Width
600 mm
Depth
697 mm
Height
max. 1838 mm
Weight
max. 180 kg, depending on
configuration

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OptiFlex A1 (AS07) Product description
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11
Further specifications will be found in the corresponding
manuals of the components.
Sound pressure level
OptiFlex A1 (AS07)
Normal operation
< 55 dB(A)
The sound pressure level was measured while the unit was in operation;
measurements were taken at the most frequent operator positions and at
a height of 1.7 m from the ground.
The specified value is applicable only for this product itself and does not
take into account external noise sources or cleaning impulses.
The sound pressure level may vary, depending on the product
configuration and space constraints.

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Product description OptiFlex A1 (AS07)
Design and function
Overall view
fig.
2
1 Base cabinet
2 Key switch
3 Pneumatic-fluidizing unit
4 Upper part with pneumatic group
and pressure regulator
5 Gun control
6 Axis control
7 Dummy cover
8 Main switch
System components
OptiFlex A1 (AS07) Control cabinet
Function
–Equipment main switch
–Key switch for switching on/off the guns
–Interlocks on the mounting plate
–Max. 15 places for gun or axis control units
–Pneumatic functions by OptiAir CA12
–Option: connectable LM02 Level sensor
OptiStar 4.0 (CG20) Gun control unit
Function
–OptiStar 4.0 (CG20) Standard Gun control
unit
–Max. 250 stored programs possible
–Communication with the Gema
electrostatic app
–DVC (Digital Valve Control)
–PCC (Precise Charge Control)

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OptiFlex A1 (AS07) Product description
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13
MultiStar CG10 Gun control unit
Function
–MultiStar CG10/CG10-X Gun control unit
–Max. 250 stored programs possible
–DVC (Digital Valve Control)
–PCC (Precise Charge Control)
OptiMove CR07/CR08 Axis control unit
Function
–Axis control unit for ZA0x Reciprocator
–Pendulum operating mode or sequence
programs
–Max. 255 stored programs possible
OptiAir CA12-A/B pneumatic-fluidizing unit
Function
–Airmover control unit
–Fluidization in the powder hopper
–Manual prefluidization
OptiAir CA09 Pneumatic-fluidizing unit
Function
–Airmover control unit
–Fluidization in the powder hopper
OptiFeed CA11 Fresh powder control unit
Function
–Controlling of the PP.. powder pump
transport air
–Monitoring of the air pressure
–Controlling the vibrator motors
Pneumatic group
Function
–Air distribution for OptiFlex A1 and gun
control units OptiStar
Pneumatic group CG10
Function
–Air distribution for OptiFlex A1 and gun
control units MultiStar

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Product description OptiFlex A1 (AS07)
Available accessories
LM02 Level sensor
Function
–Level detection in the powder hopper
Panel
Function
–Panel for versions with MultiStar CG10
For other expansion variants only limited
use, since the access to the pneumatic
group is not guaranteed.
Possible system configurations
Automatic equipment with reciprocator
fig.
3
:
1 Gun control
2 Axis control
3 Pneumatic-fluidizing unit
4 Fluidized powder hopper
with injector and Airmover
5 Vertical axis
6 Gun

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OptiFlex A1 (AS07) Product description
•
15
Automatic equipment without reciprocator
fig.
4
:
1 Gun control
4 Fluidized powder hopper
with injector and Airmover
6 Gun
Scope of delivery
The scope of delivery depends on the type and the number of installed
control units. See also "System components" on page 12.
Typical properties –characteristics of the functions
The OptiFlex A1 (AS07) Control system was especially designed to meet
the requirements of job coaters or operators of very small systems.
The flexible, modular structure of the Control system is readily adaptable
to any modifications in the installation.

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Product description OptiFlex A1 (AS07)

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OptiFlex A1 (AS07) Assembly / Connection
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17
Assembly / Connection
Assembly notes
ATTENTION
Tilting danger!
Unfitted control cabinet can fall over and cause injury or damage at
the same time.
►After unpacking and installing, the control cabinet is to be
anchored to the floor with the supplied steel bolts!
–The mounting holes are located in the profiles on both cabinet
sides.
The internal connections have already been made at the factory. The
control unit connections to the external plant parts must be done at the
start-up.
The connection possibilities for the individual control units are found in the
corresponding operating manuals.
When connecting, pay particularly attention to the length and
radii of the pneumatics hoses!

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•
Assembly / Connection OptiFlex A1 (AS07)
Fig.
5
: Set-up and assembly
1 Compressed air input
2 Main valve
3 Terminal block
* recommended
OptiFlex A1 Control cabinet
Combination examples:
–1 OptiAir with max. 15 OptiStar control units
–1 OptiAir with 2 OptiMove and 13 OptiStar control units

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OptiFlex A1 (AS07) Assembly / Connection
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Connection instructions
The Gun control unit and the System components are supplied ready for
use by the manufacturer. Just a few cables and hoses must be
connected.
Connect grounding cable to the booth or the suspension
arrangement!
–Check ground connections with Ohm meter and ensure
1 MOhm or less.
The compressed air must be free of oil and water!
Close the unused connections with the provided dust protection
caps!

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Assembly / Connection OptiFlex A1 (AS07)