Gema OptiFlex 2 B User manual

En
Translation of the original operating instructions
Operating instructions and spare parts list
Manual coating equipment
OptiFlex 2 B

V 03/13
Documentation OptiFlex 2 B
© Copyright 2010 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.
OptiFlex, OptiTronic, OptiGun, EasyTronic, EasySelect, EasyFlow,
OptiStar, OptiSelect, OptiFlow and SuperCorona are registered
trademarks of Gema Switzerland GmbH.
OptiMatic, OptiMove, OptiMaster, OptiPlus, PowerClean, Precise Charge
Control (PCC), 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
concerned approve of or are bound in any form by this manual. We have
endeavored 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
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 17
9015 St. Gallen
Switzerland
Phone: [phone]
Fax.: [phone]
E-Mail: [e-mail]
Homepage: www.gemapowdercoating.com

V 03/13
OptiFlex 2 B Table of contents •1
Table of contents
General safety regulations 3
Safety symbols (pictograms) ...................................................................................3
Conformity of use ....................................................................................................8
Product-specific safety measures ...........................................................................8
OptiFlex 2 B manual coating equipment ....................................................8
About this manual 9
General information.................................................................................................9
Product description 11
Field of application ................................................................................................11
Utilization ..................................................................................................11
Reasonably foreseeable misuse ..............................................................12
Technical data .......................................................................................................12
Connectable guns ....................................................................................12
Powder output (guide values) ..................................................................12
Guide values for OptiFlex 2 CG09 with the OptiFlow IG06 injector .........13
Air flow rates.............................................................................................13
Electrical data...........................................................................................13
Pneumatic data ........................................................................................14
Dimensions...............................................................................................14
Processible powders ................................................................................14
Design and function...............................................................................................15
General view ............................................................................................15
Scope of delivery...................................................................................................16
OptiFlex 2 B..............................................................................................16
Typical properties - Characteristics of the functions .............................................16
Processing the powder directly from the original powder manufacturer's
container...................................................................................................16
Freely rotating head piece........................................................................16
Start-up 17
Preparation for start-up .........................................................................................17
Basic conditions .......................................................................................17
Set-up ....................................................................................................................17
Mounting instructions ............................................................................................18
Connection instructions .........................................................................................19
Initial start-up 21
Set head piece ......................................................................................................22
Setting the device type ..........................................................................................22
Operation...............................................................................................................23
Coating .....................................................................................................23
Setting the background illumination .........................................................27
Color change .........................................................................................................28
General information..................................................................................28

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2 •Table of contents OptiFlex 2 B
Shutdown .............................................................................................................. 31
Cleaning and maintenance 33
Daily maintenance ................................................................................................ 33
Weekly maintenance............................................................................................. 33
If in disuse for several days ..................................................................................33
Powder hose rinsing ................................................................................ 34
Cleaning ................................................................................................................ 34
Cleaning the fluidizing/suction unit .......................................................... 34
Cleaning the OptiFlex 2 GM03 manual powder gun................................ 34
Maintenance and cleaning of the filter unit ........................................................... 35
Replacing the filter element ..................................................................... 35
Troubleshooting 37
General information .............................................................................................. 37
Spare parts list 39
Ordering spare parts ............................................................................................. 39
OptiFlex 2 B manual coating equipment – Spare parts ........................................ 40
OptiFlex 2 B manual coating equipment – Spare parts ........................................ 41
OptiFlex 2 B – Pneumatic group ........................................................................... 42

V 03/13
OptiFlex 2 B General safety regulations •3
General safety regulations
This chapter sets out the fundamental safety regulations that must be
followed by the user and any third parties using OptiFlex 2 B manual
coating equipment.
These safety regulations must be read and understood in full before the
OptiFlex 2 B is put into operation.
Safety symbols (pictograms)
The following warnings with their meanings can be found in the Gema
operating instructions. The general safety precautions must also be
followed as well as the regulations in the operating instructions.
DANGER!
Danger due to live electricity or moving parts. Possible consequences:
death or serious injury
WARNING!
Improper use of the equipment could damage the machine or cause it to
malfunction. Possible consequences: light injuries or damage to the
equipment
INFORMATION!
Useful tips and other information

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4 •General safety regulations OptiFlex 2 B
The OptiFlex 2 B Manual coating equipment is built to the latest
specification and conforms to the recognized technical safety regulations.
It 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 any such non-compliant use and the
user shall bear sole responsibility for such actions. Gema Switzerland
GmbH must be consulted prior to any use of the OptiFlex 2 B Manual
coating equipment for purposes or substances beyond those stipulated in
our guidelines.
Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of the conformity of use.
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.
Additional safety and operation notices can be found on the
accompanying CD or on the homepage www.gemapowdercoating.com.
Start-up is forbidden until it has been established that the OptiFlex 2 B
manual coating equipment has been set up and wired according to the
EU guidelines for machinery.
Unauthorized modifications to the OptiFlex 2 B Manual coating
equipment exempt the manufacturer from any liability from resulting
damages or accidents.
The operator must ensure that all users have received 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
dangers
General
Information

V 03/13
OptiFlex 2 B 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
Switzerland GmbH guarantee.
The connecting cables between the control unit and the spray gun must
be installed so as to eliminate the possibility of damage during the
operation. Safety precautions specified by local legislation must be
observed!
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 related to the use of spare parts from
other manufacturers, all relevant warranty or compensation claims are
void!
Conditions leading to dangerous levels of dust concentration in the
powder spraying booths or in the powder spraying areas must be
avoided. There must be sufficient technical ventilation available, to
prevent a dust concentration of greater 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
spraying equipment are forbidden for safety reasons.
The safety devices may not be dismantled or put out of operation.
Mandatory operational and workplace notices from the operating
company must be written in a comprehensible manner in the language of
equipment operators and posted in a suitable location.
Electrical
dangers
Explosive danger

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6 •General safety regulations OptiFlex 2 B
Powder lying on the floor around the powder spraying equipment is a
potentially dangerous source of slipping. Booths may be entered only in
the places designed for this purpose.
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 within 5 meters around each booth
opening, and in particularly the objects to be coated, must be grounded.
The grounding resistance of each object must amount to maximally
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 electrostatic manual powder coating equipment.
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 open flames are forbidden in the entire plant area! No work
that could potentially produce sparks is allowed!
Slipping
danger
No smoking or open
flames
Strict compliance
with grounding
requirements

V 03/13
OptiFlex 2 B 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
electromagnetic 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 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!
No flash
photography
Not safe for persons
with pacemakers
Separate from
power mains before
maintenance or
repairs

V 03/13
8 •General safety regulations OptiFlex 2 B
Conformity of use
1. The OptiFlex 2 B manual coating equipment is state of the art
equipment 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 damages resulting from such use; the user
bears sole responsibility for such actions. Gema Switzerland
GmbH must be consulted before OptiFlex 2 B manual coating
equipment is used for any other purposes or substances beyond
those indicated here.
3. Observance of the operating, service and maintenance
instructions specified by the manufacturer is also part of
conformity of use. The OptiFlex 2 B manual coating equipment
should only be used, maintained and started up by trained
personnel informed and familiar with the possible hazards
involved.
4. Start-up (i.e. operation of its intended use) is not allowed until it
has been established that the OptiFlex 2 B manual coating
equipment has been installed and wired according to the EU
Machinery Directive (2006/42/EC). EN 60204-1 (machine safety)
must also be observed.
5. Unauthorized modifications to the OptiFlex 2 B manual coating
equipment 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
- Installation work performed by the customer must be carried
out according to local regulations.
- All components must be grounded according to the local
regulations before start-up.
OptiFlex 2 B manual coating equipment
The OptiFlex 2 B manual coating equipment 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.
Note:
For further security information, see the more detailed Gema safety
regulations!

V 03/13
OptiFlex 2 B About this manual •9
About this manual
General information
This operating manual contains all important information required to work
with the OptiFlex 2 B manual coating equipment. 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 functionality of the individual system components -
booth, gun control unit, manual gun or powder injector - should be
referenced to their enclosed corresponding documents.

V 03/13
OptiFlex 2 B Product description •11
Product description
Field of application
The OptiFlex 2 B (with powder box) manual coating equipment 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
responsible for any incorrect use, and any associated risks 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 B manual coating equipment
Utilization
The electrostatic OptiFlex 2 B manual coating equipment with the
OptiFlex 2 GM03 manual powder gun is ideally suited for manual coating
of objects.

V 03/13
12 •Product description OptiFlex 2 B
Reasonably foreseeable misuse
- Operation without the proper training
- Use with insufficient compressed air quality and grounding
- Use in connection with unauthorized coating devices or
components
Technical data
Connectable guns
OptiFlex 2 B connectable
OptiFlex 2 GM03 yes
Warning:
The OptiFlex 2 B manual coating equipment can only be used with
the specified gun type!
Powder output (guide values)
General conditions for the OptiFlow Injector
Powder type Epoxy/polyester
Powder hose length (m) 6
Powder hose Ø (mm) 10
Powder hose type POE with guide strips
Input pressure (bar) 5,5
Conveying air nozzle Ø (mm) 1,6
Correction value C0 Powder output zeroing adjustment

V 03/13
OptiFlex 2 B Product description •13
Guide values for OptiFlex 2 CG09 with the
OptiFlow IG06 injector
All values in these tables are guide values. Differing environmental
conditions, 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
The total air consists of conveying air and supplementary air, in relation
to the selected powder quantity (in %). As a result the total air volume is
maintained constant.
OptiFlex 2 B Range Factory
setting
Flow rate - fluidizing air
- OptiFlex B 0-1.0 Nm³/h 0.1 Nm³/h
Electrode rinsing air flow rate 0-3.0 Nm³/h 0.1 Nm³/h
Flow rate total air (at 5.5 bar) 1.8-6.5 Nm³/h
Note:
The total air consumption for the device is determined based on the
3 configured air values.
These values apply for an internal control pressure of 5.5 bar!
Electrical data
OptiFlex 2 B
Nominal input voltage 100-240 VAC
Frequency 50 -60 Hz
Connected load (without vibrator) 140 VA
Nominal output voltage (to the gun) eff.10 V
Nominal output current (to the gun) max. 1.2 A
Connection and output for vibrator (on Aux
output)
110/230 VAC
max. 100 W
Connection for rinsing function (valve) 24 VDC
max. 3 W
Temperature range 0°C - +40°C
(+32°F - +104°F)
Max. surface temperature 120 °C (+248 °F)
Approvals II 3 D IP54 120 °C

V 03/13
14 •Product description OptiFlex 2 B
Pneumatic data
OptiFlex 2 B
Max. input pressure 10 bar
Min. input pressure 6 bar
Input pressure (Dynamic based on pressure
regulator setting) 5.5 bar / 80 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
Max. compressed air consumption 8 Nm³/h
Dimensions
OptiFlex 2 B
Width 460 mm
Depth 862 mm
Height 1105 mm
Weight 42 kg
Processible powders
OptiFlex 2 B
Plastic powder yes
Metallic powder yes
Enamel powder no

V 03/13
OptiFlex 2 B Product description •15
Design and function
General view
OptiFlex 2 B manual coating equipment - Structure
1 OptiFlex 2 CG09 control unit 10 Filter unit
2 OptiFlex 2 GM03 manual powder gun 11 Gun holder
3 OptiFlow injector 12 Hose holder
4 Mobile frame with hand rail 13 PowerClean module
5 Fluidizing/suction unit 14 Shelf
6 Vibrating table 15 Rubber wheel
7 Powder box 16 Swivel wheel
8 Swivel arm with guide sleeve
OptiFlex 2 GM03 manual powder gun
All information about the OptiFlex 2 CM03 manual powder gun can be
found in the documentation for that equipment (enclosed with this
manual)!
OptiFlex 2 CG09 control unit
All information about the OptiFlex 2 CG09 manual gun control unit can
found in the documentation for that equipment (enclosed with this
manual)!
OptiFlow injector
All information about the OptiFlow injector can be found in the
corresponding enclosed documentation!
2 1
3
13
5
7
16
4
8
6
15
11
12
14
10

V 03/13
16 •Product description OptiFlex 2 B
Scope of delivery
OptiFlex 2 B
- OptiFlex 2 CG09 control unit in a metal case with power
supply cable
- mobile trolley with a gun/hose support
- vibrating base and a fluidizing/suction unit
- plug-in OptiFlow injector
- OptiFlex 2 CM03 manual powder gun with gun cable,
powder hose, rinsing air hose and standard nozzle set
(For more on this, see the operating manual for the
OptiFlex 2 CM03 manual powder gun)
- Pneumatic hoses for conveying air (red), supplementary
air (black), fluidizing air (black) and rinsing air (black)
- Operating manual
- Short instructions
Typical properties - Characteristics of the functions
Processing the powder directly from the original
powder manufacturer's container
The OptiFlex 2 B manual coating equipment allows for powder to be
processed directly out of the original powder manufacturer's container. A
titled vibrating floor has been included to ensure that the powder
container empties itself completely.
Freely rotating head piece
The OptiFlex 2 B manual coating equipment features a freely rotating and
lockable head piece for more ergonomic operation and configuration.
Freely rotating head piece

V 03/13
OptiFlex 2 B Start-up •17
Start-up
Preparation for start-up
Basic conditions
When starting up the OptiFlex 2 manual coating unit, the following
general conditions impacting the coating results must be taken into
consideration:
- Manual coating equipment is set up properly
- Gun control unit correctly connected
- Gun correctly connected
- Corresponding power and compressed air supply available
- Powder preparation and powder quality
Set-up
The OptiFlex 2 B manual coating equipment should always be set up
vertically on a flat surface.
WARNING:
The manual coating equipment must not under any circumstances
be set up near a heat source (such as an enameling furnace) or an
electromagnetic source (such as a control cabinet).
If the manual equipment is being held by the bracket during
maneuvering, the fingers can potentially be crushed when the
bracket is folded down onto the control unit.

V 03/13
18 •Start-up OptiFlex 2 B
Mounting instructions
The OptiFlex 2 B manual coating equipment must be set up in
accordance with the setup and connecting instructions (included with
delivery).
Manual coating equipment OptiFlex 2 B