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

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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.

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About these instructions OptiFlex 2 F
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.
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."

Rev. 00 09/16
OptiFlex 2 F Safety

7
Safety
General information
This chapter provides the user and third parties who operate this product
with all essential safety regulations, the adherence to which is imperative.
These safety regulations must be read and understood in their entirety
before the product is put into operation.
The standards and guidelines applied during the development,
manufacture and configuration are described in the EC declaration of
conformity and in the manufacturer’s declaration.
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.
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.

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
Safety OptiFlex 2 F
–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 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
These general safety regulations must be read and understood in
all cases prior to start-up!
General information
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.
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.

Rev. 00 09/16
OptiFlex 2 F Safety

9
General dangers
Start-up is forbidden until it has been established that the product has
been set up and wired according to the EU guidelines for machinery.
Unauthorized modifications to the product exempt the manufacturer
from any liability from resulting damages or accidents.
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.
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.
Electrical danger
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
operation. 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 product may not be switched on until the booth is in operation. If the
booth stops, the product must switch off too.
Explosion hazard
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
manufacturers, the warranty or compensation claim is 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 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
spraying 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
company must be written in a comprehensible manner in the language
of equipment operators and posted in a suitable place.

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Safety OptiFlex 2 F
Slip hazard
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 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
Observe the grounding
regulations
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 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
Fire and smoke
prohibition
Smoking and igniting fire are forbidden in the entire vicinity of the
system! No work that could potentially produce sparks is allowed!
Stay for persons with cardiac pacemakers
The stay for persons
with cardiac pacemakers
is forbidden
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!

Rev. 00 09/16
OptiFlex 2 F Safety
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11
Photographing with flashlight
Photographing with
flashlight is forbidden
Photographing with flashlight can lead to unnecessary releases and/or
disconnections by safety devices.
Maintenance works
Disconnect from mains
before maintenance
works take place
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.

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
Safety OptiFlex 2 F

Rev. 00 09/16
OptiFlex 2 F OptiFlex 2 F

13
OptiFlex 2 F
For further information, see the corresponding operating manual,
which can be found on the accompanying CD.
Structure
Overall view
fig.
1
1 OptiStar CG13 Gun control unit
2 OptiSelect GM03 manual gun
3 OptiFlow injector
4 Frame
7 Fluidized powder hopper
8 AirMover
10 Filter unit
11 Gun holder
12 Hose holder
13 PowerClean module**
14 Shelf
15 Rubber wheel
16 Swivel wheel

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
OptiFlex 2 F OptiFlex 2 F
Scope of delivery
–OptiSelect GM03 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 OptiSelect GM03 manual powder gun)
–OptiStar CG13 Control unit in a metal case with power supply cable
–plug-in OptiFlow injector
–mobile trolley with a gun/hose support
–Fluidized powder hopper
–PowerClean module**
–Pneumatic hoses for conveying air (red), supplementary air (black),
fluidizing air (black) and rinsing air** (black)
–Operating manual
–Short description
Technical Data
Connectable guns
ATTENTION
The OptiFlex 2 F Manual coating equipment may only be used with the
specified gun types!
OptiFlex 2 F
connectable
OptiSelect GM03
yes
Electrical data
OptiFlex 2 F
Nominal input voltage
100-240 VAC
Frequency
50-60 Hz
Connected load (without vibrator)
40 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

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OptiFlex 2 F OptiFlex 2 F

15
Pneumatic data
OptiFlex 2 F
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
11 Nm³/h
Dimensions
OptiFlex 2 F
Width
460 mm
Depth
832 mm
Height
1105 mm
Weight
46 kg
Processible powders
OptiFlex 2 F
Plastic powder
yes
Metallic powder
yes
Enamel powder
no
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
Correction value C0
Powder output zeroing
adjustment

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OptiFlex 2 F OptiFlex 2 F
Guide values for OptiStar CG13 with OptiFlow Injector
IG06
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 F
Range
Factory
setting
Flow rate –fluidizing air:
0-5.0 Nm³/h
1.0 Nm³/h
Electrode rinsing air flow rate
0-5.0 Nm³/h
0.1 Nm³/h
Flow rate total air (at 5.5 bar)
5 Nm³/h
–Conveying air flow rate
0-5.4 Nm³/h
–Supplementary air flow rate
0-4.5 Nm³/h
The max. total air consumption during the coating operation is
< 5,5 Nm³/h:
–Total air = 5 Nm³/h (conveying air + supplementary air)
–Electrode rinsing air = 0,1 Nm³/h (flat jet nozzle)
The total air consumption for the device is determined based on
the 3 configured air values (without AirMover air value).
–These values apply for an internal control pressure of 5.5 bar!

Rev. 00 09/16
OptiFlex 2 F Assembly / Connection

17
Assembly / Connection
Connection instructions
fig.
2
: Connecting guide –overview
1 Electrode rinsing air hose
2 OptiSelect GM03 manual
gun
9 PowerClean™ module
(Option)
10 Compressed air hose

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
Assembly / Connection OptiFlex 2 F
3 Gun cable
4 Powder hose
5 Supplementary air hose
6 Conveying air hose
7 Control signal cable
8 Injector
11 Fluidizing air hose
12 Maintenance unit
13 OptiStar CG13 Gun control
unit
14 Rinsing air hose
15 AirMover
16 Fluidized powder hopper
Use clamp to connect grounding cable to the cabin or the
suspension arrangement!
►Check ground connections with Ohm meter and ensure 1
MOhm or less!
Close the unused connections with the provided dust protection
caps!
►If no vibration motor (OptiFlex B) is connected, close the 2.2
Aux output with the dust protection cap!
►If no PowerClean module is connected, close also the 2.4
Purge connection with the dust protection cap!
The compressed air must be free of oil and water!
Connections
Compressed air hoses / cables
fig.
3
: Connections
Connection
Description
1.1 Main air IN
Compressed air connection
2.1 Power IN
Mains cable connection
2.2 Aux
Vibration motor connection for OptiFlex 2 B
2.3 Gun
Gun cable connection

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OptiFlex 2 F Assembly / Connection
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19
Connection
Description
2.4 Power Clean
Connection to rinsing module
1.2
Conveying air connection
1.3
Supplementary air connection
1.4
Electrode rinsing air connection
1.5
Fluid air connection
Grounding connection
Set head piece
1.
2.
3.

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Assembly / Connection OptiFlex 2 F