Gema OptiFlex 2 V Guide

En
Translation of the original operating instructions
Operating instructions and spare parts list
Fresh powder system
OptiFlex 2 V

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Documentation OptiFlex 2 V
© Copyright 2010 Gema Switzerland GmbH
All rights reserved.
This publication is protected by copyright. Unauthorized copying is prohib-
ited 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.
OptiFlex, OptiTronic, OptiGun, EasyTronic, EasySelect, EasyFlow, Op-
tiStar, OptiSelect, OptiFlow and SuperCorona are registered trademarks
of Gema Switzerland GmbH.
OptiMatic, OptiMove, OptiMaster, OptiPlus, PowerClean, Precise Charge
Control (PCC), OptiSpray, MultiTronic 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 con-
cerned approve of or are bound in any form by this manual. We have en-
deavored 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 Swit-
zerland 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 17
9015 St.Gallen
Switzerland
Phone: [phone]
Fax.: [phone]
E-mail: [email protected]
Homepage: www.gemapowdercoating.com

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OptiFlex 2 V Table of contents • 1
Table of contents
General safety regulations 3
Safety symbols (pictograms) ................................................................................... 3
Intended use ........................................................................................................... 8
Product-specific safety measures ........................................................................... 8
OptiFlex 2 V Fresh powder system ............................................................ 8
About this manual 9
General information ................................................................................................ 9
Product description 11
Field of application ................................................................................................ 11
Utilization .................................................................................................. 11
Reasonably foreseeable misuse .............................................................. 12
Technical Data ...................................................................................................... 12
Powder output (reference values) ............................................................ 12
Guide values for OptiStar with OptiFlow Injector IG06 ............................ 12
Air flow rates ............................................................................................ 12
Electrical data .......................................................................................... 13
Dimensions .............................................................................................. 13
Processible powders ................................................................................ 13
Design and function .............................................................................................. 14
Overall view.............................................................................................. 14
Scope of delivery .................................................................................................. 14
OptiFlex 2 V ............................................................................................. 14
Optional accessories for OptiFlex 2 V ..................................................... 15
Typical characteristics – properties of the functions ............................................. 15
Processing the powder directly from the original powder manufacturer's
container .................................................................................................. 15
Start-up 17
Preparation for start-up ......................................................................................... 17
Basic conditions ....................................................................................... 17
Set-up .................................................................................................................... 17
Assembly guide ..................................................................................................... 18
Connection instructions ......................................................................................... 19
Initial start-up 21
Operation .............................................................................................................. 22
Coating ..................................................................................................... 22
Color change ......................................................................................................... 23
General information ................................................................................. 23
Shutdown .............................................................................................................. 25
Cleaning and maintenance 27
Daily maintenance ................................................................................................ 27
Weekly maintenance ............................................................................................. 27

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2 • Table of contents OptiFlex 2 V
If in disuse for several days .................................................................................. 27
Powder hose rinsing ................................................................................ 27
Cleaning ................................................................................................................ 28
Cleaning the fluidizing/suction unit .......................................................... 28
Troubleshooting 29
General information .............................................................................................. 29
Spare parts list 31
Ordering spare parts ............................................................................................. 31
OptiFlex 2 V fresh powder system – Spare parts list ........................................... 32
OptiFlex 2 V fresh powder system – Spare parts list ........................................... 33

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OptiFlex 2 V General safety regulations • 3
General safety regulations
This chapter sets out the fundamental safety regulations that must be fol-
lowed by the user and third parties using OptiFlex 2 V Fresh powder sys-
tem.
These safety regulations must be read and understood before the
OptiFlex 2 V is put into operation.
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 fol-
lowed .
DANGER!
danger due to live electricity or moving parts. Possible consequences:
Death or serious injury
ATTENTION!
improper use of the equipment could damage the machine or cause it to
malfunction. Possible consequences: minor injuries or damage to equip-
ment
INFORMATION!
useful tips and other information

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4 • General safety regulations OptiFlex 2 V
The OptiFlex 2 V Fresh powder system is state of the art equipment that
conforms to the recognized technical safety regulations and is designed
for normal powder coating applications.
Any other use is considered non-compliant. The manufacturer shall not be
liable for damage resulting from such use; the user bears sole responsibil-
ity for such actions. If the OptiFlex 2 V 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 speci-
fied by the manufacturer is also part of conformity of use.
The relevant accident prevention regulations, as well as other generally
recognized safety regulations, occupational health and structural regula-
tions are to be observed.
Furthermore, the country-specific safety regulations also must be ob-
served.
Additional safety and operation notices can be found on the accompany-
ing CD or on the homepage www.gemapowdercoating.com.
Start-up is forbidden until it has been established that the OptiFlex 2 V
fresh powder system has been set up and wired according to the EU
guidelines for machinery.
Unauthorized modifications to the OptiFlex 2 V fresh powder system ex-
empt the manufacturer from any liability from resulting damages or acci-
dents.
The operator must ensure that all users do have the appropriate training
for powder spraying equipment and are aware of the possible sources of
danger.
Any operating method, which will negatively influence the technical safety
of the powder spraying equipment, is to be avoided.
General dan-
gers
General in-
formation

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OptiFlex 2 V General safety regulations • 5
For your own safety, only use accessories and attachments listed in the
operating instructions. The use of other parts can lead to risk of injury.
Only original Gema spare parts should be used!
Repairs must only be carried out by specialists or by authorized Gema
service centers. Unauthorized conversions and modifications can lead to
injuries and damage to the equipment and invalidate the Gema Switzer-
land GmbH guarantee.
The connecting cables between the control unit and the spray gun must
be installed in such a way, that they cannot be damaged during the op-
eration. Please observe the local safety regulations!
The plug connections between the powder spraying equipment and the
mains should only be removed when the power supply is switched off.
All maintenance activities must take place when the powder spraying
equipment is switched off.
The powder coating equipment may not be switched on until the booth is
in operation. If the booth stops, the powder coating device must switch off
too.
The control units for the spray guns must be installed and used in zone
22. Spray guns are allowed in zone 21.
Only original Gema OEM parts are guaranteed to maintain the explosion
protection rating. If damages occur by using spare parts from other manu-
facturers, the warranty or compensation claim is void!
Conditions leading to dangerous levels of dust concentration in the pow-
der spraying booths or in the powder spraying areas must be avoided.
There must be sufficient technical ventilation available, to prevent a dust
concentration of more than 50% of the lower explosion limit (UEG = max.
permissible powder/air concentration). If the UEG is not known, then a
value of 10 g/m³ should be considered (see EN 50177).
All unauthorized conversions and modifications to the electrostatic spray-
ing equipment are forbidden for safety reasons.
No safety devices should be dismantled or put out of operation.
Mandatory operational and workplace notices from the operating compa-
ny must be written in a comprehensible manner in the language of
equipment operators and posted in a suitable place.
Electrical
danger
Explosion hazard

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6 • General safety regulations OptiFlex 2 V
Powder lying on the floor around the powder spraying equipment is a po-
tentially dangerous source of slipping. Booths may be entered only in the
places suitable for it.
Static charges
Static charges can have the following consequences: Charges to people,
electric shocks, sparking. Proper grounding must be in place to prevent
objects from becoming charged.
Grounding
All electrically conductive parts found in the workplace of 5 meters around
each booth opening, and particularly the objects to be coated, have to be
grounded. The grounding resistance of each object must amount to max-
imally 1 MOhm. This resistance must be checked/tested regularly when
starting work.
The condition of the work piece attachments, as well as the hangers,
must guarantee that the work pieces remain grounded. The appropriate
measuring devices must be kept ready in the workplace, in order to check
the grounding.
The floor of the coating area must conduct electricity (normal concrete is
generally conductive).
The supplied grounding cable (green/yellow) must be connected to the
grounding screw of the fresh powder system. The grounding cable must
have a good metallic connection with the coating booth, the recovery unit
and the conveyor chain, respectively with the suspension arrangement of
the objects.
Smoking and igniting fire are forbidden in the entire vicinity of the system!
No work that could potentially produce sparks is allowed!
Slip hazard
Observe the ground-
ing regulations
Fire and smoke pro-
hibition

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OptiFlex 2 V General safety regulations • 7
As a general rule for all powder spraying installations, persons with
pacemakers should never enter high voltage areas or areas with electro-
magnetic fields. Persons with pacemakers should not enter areas with
powder spraying installations!
Photographing with flashlight can lead to unnecessary releases and/or
disconnections by safety devices.
Disconnect the plugs before the machines are opened for maintenance or
repair.
The plug connections between the powder spraying equipment and the
mains should only be removed when the power supply is switched off.
As far as it is necessary, the operating firm must ensure that the operating
personnel wear protective clothing (e.g. facemasks).
A dust mask corresponding to filter class FFP2 or N95 at minimum must
be worn during any cleaning work.
The operating personnel must wear electrically conductive, steel-toe
footwear (e.g. leather soles).
The operating personnel should hold the gun with bare hands. If gloves
are worn, these must also conduct electricity.
These general safety regulations must
be read and understood in all cases
prior to start-up!
The stay for persons
with cardiac pace-
makers is forbidden
Photographing with
flashlight is forbid-
den
Disconnect from
mains before
maintenance works
take place

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8 • General safety regulations OptiFlex 2 V
Intended use
1. The OptiFlex 2 V Fresh powder system is state of the art equip-
ment that conforms to the recognized technical safety regulations
and is designed for normal powder coating applications.
2. 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 the OptiFlex 2 V is to
be used for other purposes or other substances outside of our
guidelines then Gema Switzerland GmbH should be consulted.
3. Observance of the operating, service and maintenance instruc-
tions specified by the manufacturer is also part of conformity of
use. The OptiFlex 2 V should only be used, maintained and
started up by trained personnel, who are informed about and are
familiar with the possible hazards involved.
4. Start-up (i.e. the execution of a particular operation) is forbidden
until it has been established that the OptiFlex 2 V has been set
up and wired according to the guidelines for machinery (2006/42
EG). EN 60204-1 (machine safety) must also be observed.
5. Unauthorized modifications to the OptiFlex 2 V fresh powder sys-
tem exempt the manufacturer from any liability from resulting
damage.
6. The relevant accident prevention regulations, as well as other
generally recognized safety regulations, occupational health and
structural regulations are to be observed.
7. Furthermore, the country-specific safety regulations also must be
observed.
Product-specific safety measures
- 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 accord-
ing to the local regulations before start-up.
OptiFlex 2 V Fresh powder system
The OptiFlex 2 V fresh powder system is a constituent part of the equip-
ment 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.
NOTE:
For further information, see the more detailed Gema safety regula-
tions.

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OptiFlex 2 V About this manual • 9
About this manual
General information
This operating manual contains all important information which you re-
quire for the working with the OptiFlex 2 V Fresh powder system. 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 function mode of the individual system components
– booth, gun control unit, manual gun or powder injector – can be found in
the supplied documents.
NOTE:
These operating instructions describe all the features and functions
of the fresh powder system that were available at the time this oper-
ating instructions went to press.
Please note that your fresh powder system may not be equipped
with all described functions.

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OptiFlex 2 V Product description • 11
Product description
Field of application
The OptiFeed 2 V Fresh powder system (with powder box) is exclusively
intended for electrostatic coating using organic powders (For more on this
please also review chapter "Technical Data").
Any other use is considered non-compliant. The manufacturer is not re-
sponsible for any incorrect use and the risks associated with such actions
are assumed by the user alone!
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.
OptiFlex 2 V Fresh powder system
Utilization
The fresh powder system is ideally suited for the powder supply for one or
two manual or automatic powder guns with synthetic fresh powder directly
from the powder container. The powder will be vibrated in its container
and directly sucked up by the fluidizing/suction unit.

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12 • Product description OptiFlex 2 V
Reasonably foreseeable misuse
- Operation without the proper training
- Use with insufficient compressed air quality and grounding
- Use in connection with unauthorized coating devices or com-
ponents
Technical Data
Powder output (reference values)
General conditions for the OptiFlow Injector
Powder type Epoxy/polyester
Length of powder hose (m) 6
Powder hose Ø (mm) 10
Type of powder hose POE with guide strips
Input pressure (bar) 5.5
Conveying air nozzle (mm) 1.6
Correction value C0 Powder output zeroing adjust-
ment
Guide values for OptiStar with OptiFlow Injector
IG06
All values in these tables are guide values. Differing environmental condi-
tions, wear and different powder types can affect the table values.
Total air 3 Nm³/h 4 Nm³/h 5 Nm³/h
Powder output (g/min)
Powder output (%) 20 85 100 120
40
150 185 210
60 210 255 280
80 270 320 350
100 300 360 395
Air flow rates
OptiFlex 2 V Range Factory set-
ting
Flow rate – fluidizing air: 0-1.0 Nm³/h 0.1 Nm³/h

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OptiFlex 2 V Product description • 13
Electrical data
OptiFlex 2 V
Vibrator connection and performance 110/230 VACmax. 100 W
Frequency 50-60 Hz
Temperature range 0 °C - +40 °C
(+32 °F - +104 °F)
Max. surface temperature 120 °C (+248 °F)
Approvals II 3 D IP54 120 °C
Dimensions
OptiFlex 2 V
Width 460 mm
Depth 862 mm
Height 900 mm
Weight 32 kg
Processible powders
OptiFlex 2 V
Plastic powder yes
Metallic powder yes
Enamel powder no

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14 • Product description OptiFlex 2 V
Design and function
Overall view
OptiFlex 2 V Fresh powder system – Structure
1 OptiFlow injector 5 Swivel wheel
2 Swivel arm with guide sleeve 6 Rubber wheel
3 Fluidizing/suction unit 7 Frame
4 Vibrating table 8 Hose holder
OptiFlow injector
All information about the OptiFlow injector will be found in the correspond-
ing enclosed documentation!
Scope of delivery
OptiFlex 2 V
- Mobile frame with hose holder
- vibrating base and a fluidizing/suction unit
- plug-in OptiFlow injector
- Pneumatic hoses for conveying air (red), supplementary
air (black) and fluidizing air (black)
- Operating manual
- Short description
8
7
6
5
3
1
4
2

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OptiFlex 2 V Product description • 15
Optional accessories for OptiFlex 2 V
- A second fluidizing/suction unit with plug-in OptiFlow in-
jector, double arm, pneumatic kit and screw joints
- Pneumatic hoses for conveying air (red) and fluidizing air
(black)
Typical characteristics – properties of the functions
Processing the powder directly from the original
powder manufacturer's container
The OptiFlex 2 V fresh powder system allows for powder to be processed
directly out of the original powder manufacturer's container. A titled vibrat-
ing floor has been included to ensure that the powder container empties
itself completely.

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OptiFlex 2 V Start-up • 17
Start-up
Preparation for start-up
Basic conditions
When starting up the OptiFlex 2 V Fresh powder system, the following
general conditions impacting the coating results must be taken into con-
sideration:
- fresh powder system is set up properly
- corresponding power supply available
- device grounded properly
- Powder preparation and powder quality
Set-up
The OptiFlex 2 V fresh powder system should always be set up vertically
on a flat surface.
WARNING:
The fresh powder system must not under any circumstances be set
up near a heat source (such as an enameling furnace) or an elec-
tromagnetic source (such as a control cabinet).

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18 • Start-up OptiFlex 2 V
Assembly guide
The OptiFlex 2 V fresh powder system must be set up in accordance with
the following setup and connecting instructions.
OptiFlex 2 V Fresh powder system