Gema OptiFlex 2 F User manual

Rev. 00 1007 142 EN
Quick reference guide
Manual equipment
OptiFlex 2 F
Translation of the original operating instructions

Rev. 00 09/16
Documentation OptiFlex 2 F
© Copyright 2016 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 and OptiStar 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) und
SuperCorona 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.
For the latest information about Gema products, visit
www.gemapowdercoating.com.
For patent information, see 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]

Rev. 00 09/16
OptiFlex 2 F Table of contents

3
Table of contents
About these instructions 5
General information ................................................................................................5
Keeping the Manual................................................................................................5
Safety symbols (pictograms)...................................................................................5
Presentation of the contents...................................................................................6
Safety 7
General information ................................................................................................7
Basic safety instructions .........................................................................................7
Product specific security regulations ......................................................................8
OptiFlex 2 F 13
Structure................................................................................................................13
Scope of delivery ..................................................................................................14
Technical Data......................................................................................................14
Assembly / Connection 17
Connection instructions.........................................................................................17
Set head piece......................................................................................................19
Start-up 21
Initial start-up.........................................................................................................21
Setting the device type..........................................................................................22
Operation 23
Operation ..............................................................................................................23
Rinsing mode........................................................................................................27
Color change.........................................................................................................30
Decommissioning / Storage 33
Decommissioning..................................................................................................33
Maintenance / Repairs 35
General information ..............................................................................................35
Interval ..................................................................................................................35
Cleaning................................................................................................................37
Fault clearance 39
OptiStar CG13 41
Design and function..............................................................................................41

Rev. 00 09/16
4

Table of contents OptiFlex 2 F
Fault clearance 45
Error diagnosis of the software............................................................................. 45
OptiSelect GM03 49
Structure............................................................................................................... 49
Scope of delivery.................................................................................................. 50
Available accessories**........................................................................................ 50
Technical Data...................................................................................................... 51
Fault clearance 53
OptiFlow IG06 55
Structure............................................................................................................... 55
Powder volume setting for OptiFlow Injector........................................................ 56
Maintenance / Repairs 57
Cleaning................................................................................................................ 57
Cleaning the injector............................................................................................. 57
Cleaning the check valve units............................................................................. 58
Replacing the insert sleeve .................................................................................. 59
Fault clearance 61
Faults.................................................................................................................... 61
Spare parts list 63
Ordering spare parts............................................................................................. 63
OptiFlex 2 F –Spare parts list.............................................................................. 64
OptiFlex 2 F –Spare parts ................................................................................... 65
Pneumatic group .................................................................................................. 66
PowerClean module set**..................................................................................... 67
OptiStar CG13 Gun control unit............................................................................ 68
Front plate and power pack.................................................................................. 69
Inside back plate................................................................................................... 70
Connecting material.............................................................................................. 71
OptiSelect GM03 –Spare parts list...................................................................... 72
PowerClean™ module (Option)............................................................................ 74
SuperCorona ........................................................................................................ 75
Accessories .......................................................................................................... 76
OptiFlow IG06 –spare parts list........................................................................... 81
OptiFlow IG06 –spare parts................................................................................. 82

Rev. 00 09/16
OptiFlex 2 F About these instructions

5
About these instructions
General information
This operating manual contains all important information which you
require for the working with the OptiFlex 2 F. 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.
This operating manual describes all options and functions of this
manual coating equipment.
–Please note that your manual coating equipment may not be
equipped with all described functions.
–Options are marked by double asterisks**.
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.