Gema OptiFlex A2 Guide

En
Translation of the original operating instructions
Operating instructions and spare parts list
OptiFlex A2
Control system
(AS08 type)

V 03/17
Documentation – Control system OptiFlex A2 (AS08)
© Copyright 2012 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.
MagicCompact, MagicCylinder, MagicPlus, MagicControl, OptiFlex,
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registered trademarks of Gema Switzerland GmbH.
OptiFlow, OptiCenter, OptiMove, OptiSpeeder, OptiFeed, OptiSpray,
OptiSieve, OptiAir, OptiPlus, OptiMaster, MultiTronic, EquiFlow, Precise
Charge Control (PCC), Smart Inline Technology (SIT) and Digital Valve
Control (DVC) 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
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To the best of our knowledge and belief, the information contained in this
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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.
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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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OptiFlex A2 (AS08) Table of contents •1
Table of contents
About this instructions 3
General information ................................................................................................3
Keeping the manual ................................................................................................3
Safety symbols (pictograms)...................................................................................3
Presentation of the contents ...................................................................................4
Figure references in the text ......................................................................4
Safety 5
General information ................................................................................................5
Intended use ...........................................................................................................5
Product-specific safety measures ........................................................................... 6
Product description 7
Field of application ..................................................................................................7
Scope of delivery ....................................................................................................7
OptiFlex A2 Control system – components ............................................................8
OptiFlex A2 Control system – possible configurations ...........................................9
Automatic equipment .................................................................................9
Automatic equipment with superordinated control unit............................10
Technical Data ......................................................................................................10
Electrical data ..........................................................................................10
Pneumatic data ........................................................................................11
Control cabinet dimensions......................................................................11
ICS cabinet dimensions ...........................................................................11
Start-up 13
Set-up and assembly ............................................................................................13
Assembly notes........................................................................................13
Configuration............................................................................................13
OptiFlex A2 .............................................................................................. 14
OptiFlex A2 with MagicControl CM30......................................................14
Start-up .................................................................................................................15
General information .................................................................................15
Power supply............................................................................................15
Compressed air........................................................................................16
Spare parts list 17
Ordering spare parts ............................................................................................. 17
Control cabinet – spare parts list ..........................................................................18
Control cabinet – spare parts................................................................................19

V 03/17
OptiFlex A2 (AS08) About this instructions •3
About this instructions
General information
This operating manual contains all important information you will need to
work with the OptiFlex A2 (AS08). It will safely guide you through the
start-up process and give you references and tips for the optimal use of
your new 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 contains a list of warnings with their meanings found in the
Gema operating instructions. Apart from the regulations in the relevant
operating instructions, the general safety precautions must also be
followed .
DANGER
Indicates a hazardous situation which,
if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which,
if not avoided, could result in minor or moderate injury.

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4 •About this instructions OptiFlex A2 (AS08)
ATTENTION
Indicates a potentially harmful situation which,
if not avoided, the equipment or something in its surrounding may be
damaged.
ENVIRONMENT
Indicates a potentially harmful situation which,
if not avoided, may have harmful consequences for the environment.
NOTE
Useful tips and other information.
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.

V 03/17
OptiFlex A2 (AS08) Safety •5
Safety
General information
This chapter sets out the fundamental safety regulations that must be
followed by the user and third parties using the OptiFlex A2 (AS08)
control system.
These safety regulations must be read and understood in full before the
OptiFlex A2 (AS08) control system is put into operation.
WARNING
Working without operating instructions
Working without operating instructions or with individual pages
from the operating 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 on "Safety regulations".
►Work should only be carried out in accordance with the
instructions in the relevant documents.
►Always work with the complete original document.
Intended use
– 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.
– 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.
– Start-up (i.e. the execution of intended operational tasks) is
forbidden until it has been established that this product has been set

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6 •Safety OptiFlex A2 (AS08)
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.
Product-specific safety measures
– 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 detailed Gema safety .

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OptiFlex A2 (AS08) Product description •7
Product description
Field of application
The OptiFlex A2 Control system with the Gema automatic powder guns
was especially designed to meet the requirements of serial production in
industry, where reliability in automated operation, easy to handle
operation and security are the most projecting advantages for the user.
The flexible, modular structure of the OptiFlex A2 Control system is
readily adaptable to any modifications in the installation.
Scope of delivery
The scope of delivery depends on the type and the number of installed
control units (For additional information see chapter "OptiFlex A2 Control
system – components").

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8 •Product description OptiFlex A2 (AS08)
OptiFlex A2 Control system – components
These components are assembled according to client's plant
specifications. Further information about the components will be
found in the corresponding operating manuals.
OptiFlex A2 control cabinet Function
– Equipment main switch
– Air supply
– Max. 21 places for gun or axle control units per
control cabinet
– Option: Master control unit for the complete
integration of the plant into the production
process by CAN bus
OptiStar CG08 Gun control unit Function
– OptiStar CG08 standard gun control unit
– Max. 250 stored programs possible
– DVC (Digital Valve Control)
– PCC (Precise Charge Control)
– Option: CAN bus
OptiMove CR07 axis control unit Function
– Axis control unit for ZA0x Reciprocator and
XTxx Horizontal axis
– Pendulum operating mode or sequence
programs
– Max. 255 stored positions possible
Magic Control CM30Plant control Function
– Master control unit
– Communication by CAN bus
– 12" Touch Screen
– Flash Card for programs and parameters
OptiControl CM22 Master control unit Function
– Master control unit
– Communication by CAN bus
– 5.7" Touch Screen
– Flash Card for parameters
OptiControl CM03 Integrated master
control unit Function
– Interlocking functions
– Gap control
– Monitoring the powder level in the powder
hopper

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OptiFlex A2 (AS08) Product description •9
OptiAir CA09 Pneumatic-fluidizing unit Function
– Automatic prefluidization
– Airmover control unit
– Fluidization in the powder hopper
LM02 Level sensor Function
Level detection in the powder hopper
OptiFlex A2 Control system – possible configurations
Automatic equipment
fig. 1:
Control units Fluidized powder hopper
with injector and Airmover
Reciprocator with guns

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10 •Product description OptiFlex A2 (AS08)
Automatic equipment with superordinated
control unit
fig. 2:
Control units Fluidized powder hopper
with injector, Airmover and
level sensor
Reciprocator with guns
Technical Data
Electrical data
OptiFlex A2
Main input voltage
3 x 400 VAC+N+PE
100-120 VAC (USA with
transformer)
Device input voltage
100-240 VAC (for gun control
units)
200-240 VAC (for axis control
units)
Frequency 50/60 Hz
Input power value 40 VA per gun control unit
1.1 VA per axis control unit
Temperature range (operation) 10-40 °C / 50-104 °F
Protection type (control units) IP54
Approval ATEX zone 22
Interlockings

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OptiFlex A2 (AS08) Product description •11
Pneumatic data
OptiFlex A2
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
Max. oil vapor content of the
compressed air 0.1 mg/m³
Total air consumption 8 Nm³/h per gun (plus powder
hopper air requirement)
Control cabinet dimensions
OptiFlex A2
Width 600 mm
Depth 697 mm
Height max. 1931 mm
ICS cabinet dimensions
OptiFlex A2
Width 1500 mm
Depth 700 mm
Height 1931 mm
Further specifications will be found in the corresponding
manuals of the components!

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OptiFlex A2 (AS08) Start-up •13
Start-up
Set-up and assembly
Assembly notes
CAUTION
Tilting danger!
►After unpacking and installing the OptiFlex system, the control
cabinet is to be fitted to the floor with the supplied steel bolts.
►The mounting holes are located in the control cabinet base.
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 attention particularly to the length and the
radii of the pneumatics hoses!
Configuration
A maximum of up to 21 control units can be installed. OptiFlex A2 control
cabinets can be laterally lined up without gap, and/or be set up at a wall.
Not used openings are covered with blind plates. These are screwed on
and can be easily removed, when possible extension of the OptiFlex A2
Control system.

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14 •Start-up OptiFlex A2 (AS08)
OptiFlex A2
fig. 3: Set-up
Optionally:
– Max. 21 CG08 Gun control units or mixed with:
– CR07 Axis control unit
– CA09 Pneumatic-fluidizing unit
– MagicControl CM30 Master control unit
– OptiControl CM22 Master control unit
OptiFlex A2 with MagicControl CM30
fig. 4: OptiFlex A2 with MagicControl CM30

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OptiFlex A2 (AS08) Start-up •15
Start-up
General information
These general information serves to obtain an overview of the possible
OptiFlex A2 system combinations.
Detailed information will be found in the corresponding operating
manuals!
Power supply
– The power supply is dependent on the type and the number of
control units:
– Stand alone – 1x100-230 V / 50/60 Hz
– Full extension – 3x400 V+N+PE / 50/60 Hz
– The input power value is plant-specific and evident in the provided
wiring diagram
– All electrical components are implemented in accordance to IP54
protection type regulations
ATTENTION
The OptiFlex A2 control system may can be switched on only if the
booth is in operation!
►If the booth switches off, the control system must also switch off!

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16 •Start-up OptiFlex A2 (AS08)
Compressed air
– The OptiFlex A2 Control system just requires a connection to the
main compressed air system
– The compressed air values are evident in the technical data section
Air requirement with increased powder output
The control system offers the possibility to work with increased powder
output in sufficiently dimensioned compressed air systems. The pressure
regulator on the filter unit is preset by factory to 5.5. If another value is set
on the pressure regulator, then the system parameter P02 on each
OptiStar Control unit needs to be adjusted according to the following
instructions:
In order to achieve the largest accuracy, the air pressure is to be
set during operation by average compressed air consumption!
> 5 s
Compressed air setting - parameter setting
OptiStar CG08 automatic gun control unit
Conversion bar-psi
5.5 bar = 80 psi
6.0 bar = 87 psi
6.5 bar = 94 psi
5.5 6.0
6.5

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OptiFlex A2 (AS08) Spare parts list •17
Spare parts list
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 Control system OptiFlex A2 (AS08)
Serial number 1234 5678
– Order no. 203 386, 1 piece, Clamp – Ø 18/15 mm
When ordering cable or hose material, the required length must also be
given. The spare part numbers of this bulk stock is always marked with an
*.
Wearing parts are always marked with a #.
All dimensions of plastic hoses are specified with the external and internal
diameter:
Example:
Ø 8/6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d)
ATTENTION
Use of non-original Gema spare parts
When using the spare parts from other manufacturers the
explosion protection is no longer guaranteed. If any damage is
caused by this use all guarantee claims become invalid!
►Only original Gema spare parts should be used!

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18 •Spare parts list OptiFlex A2 (AS08)
Control cabinet – spare parts list
1 Double nipple – 3/4"-3/4" 1012 862
2 Hexagon nut – 3/4" 1002 348
3 T-piece – 3/4"-3/4"-3/4" 1005 129
4 Sealing plug – 1/4" 203 300
(4.1) Adapter nipple – 1/4"-3/4" 1005 130
5 Pressure switch – 1-10 bar, 1/4"-PG7 (optionally – according to order) 233 757
6 Solenoid valve – 1/2", NW 13.5 mm (without pos. 6.1) 1005 121
6.1 Valve coil – 230 VAC (not shown) 1005 117
Valve coil – 110 VAC (not shown) 1005 116
Valve coil – 24 VDC (not shown) 1005 119
7 Elbow joint – 3/4"-3/4" 1011 808
8 Adapter nipple – 1"-3/4" 1005 128
9 Sealing plug – 3/8" 266 965
10 Compressed air distributor – 24-fold 1006 649
11 Plug cap – 1" 258 679
12 Pressure gauge 1015 297
13 Connection sleeve – 1/8"- Ø 6 mm 233 412
14 Plug – Ø 8 mm 238 023
17 Mounting plate, system-dependent – see enclosed wiring diagram
Pressure regulating unit – complete, pos. 20-29 1010 965
20 R/F unit – 0.5-8 bar, 1" 1006 547
21 Pressure gauge – 0-10 bar, 1/4" 1010 964
23 Adapter – 3/4"-3/4" 259 632
24 Double nipple – 3/4"-3/4" divisible 243 574
25 Elbow joint 3/4"-3/4" 1005 140
26 Double nipple – 3/4"-3/4" 1005 567
27 Elbow joint – 3/4"-3/4" 259 233
28 Adapter nipple – 1"-3/4" 1005 128
29 Hose connector – Ø 25 mm, 3/4" 1011 809
Further specifications will be found in the corresponding
manuals and spare parts list of the components!