Gema OptiFlex Pro BN Guide

Rev. 01 1017 972 EN
Operating instructions and Spare parts list
Manual equipment
OptiFlex Pro BN
This equipment was developed for use with electrically non-
conducting powders. The use of electrically conducting powders
(like metallic or graphite powders) can cause a permanent
decrease of functioning.
Translation of the original operating instructions

Rev. 01 08/20
Documentation OptiFlex Pro BN
© Copyright 2019 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]

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OptiFlex Pro BN Table of contents
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3
Table of contents
About these instructions 5
General information ................................................................................................5
Keeping the Manual................................................................................................5
Safety symbols (pictograms)...................................................................................5
Structure of Safety Notes...........................................................................6
Presentation of the contents...................................................................................6
Figure references in the text......................................................................6
Safety 7
General information ................................................................................................7
Basic safety instructions .........................................................................................7
Product description 13
Intended use .........................................................................................................13
Reasonably foreseeable misuse..............................................................14
Structure................................................................................................................14
Overall view..............................................................................................14
Scope of delivery ..................................................................................................15
Typical characteristics –properties of the functions.............................................16
Processing the powder from the stirrer recipient.....................................16
Technical Data......................................................................................................17
Connectable guns....................................................................................17
Electrical data ..........................................................................................17
Pneumatic data........................................................................................17
Dimensions ..............................................................................................18
Processible powders................................................................................18
Environmental conditions.........................................................................18
Sound pressure level...............................................................................18
Rating plate..............................................................................................19
Assembly / Connection 21
Set-up....................................................................................................................21
Assembly guide.....................................................................................................21
Connection instructions.........................................................................................22
Adaptor for external triggered powder guns (Boron Nitride Adapter)...................23
Start-up 25
Preparation for start-up.........................................................................................25
Basic conditions.......................................................................................25
Initial start-up.........................................................................................................26
Setting the device type..........................................................................................26
Operation 27
Operation ..............................................................................................................27
Select predefined operating mode (Preset mode)...................................28
Starting the individual adjustable programs.............................................28

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Table of contents OptiFlex Pro BN
Setting powder output and powder cloud................................................ 29
Setting the electrode rinsing air............................................................... 30
Rinsing mode........................................................................................................ 31
Activating the rinsing function.................................................................. 31
Setting the background illumination ..................................................................... 34
Color change ........................................................................................................ 35
General information................................................................................. 35
Decommissioning / Storage 37
Shutdown.............................................................................................................. 37
If in disuse for several days..................................................................... 37
Storage conditions................................................................................................ 37
Hazard notes........................................................................................... 37
Type of storage........................................................................................ 37
Storage duration...................................................................................... 37
Space requirements ................................................................................ 37
Physical requirements............................................................................. 38
Maintenance during storage................................................................................. 38
Maintenance schedule............................................................................. 38
Maintenance works.................................................................................. 38
Maintenance / Repairs 39
General information.............................................................................................. 39
Interval.................................................................................................................. 39
Daily maintenance................................................................................... 39
Weekly maintenance............................................................................... 39
Biannually maintenance .......................................................................... 40
If in disuse for several days..................................................................... 40
Gun maintenance.................................................................................... 40
Maintenance of the filter unit................................................................... 40
Cleaning................................................................................................................ 42
Gun cleaning ........................................................................................... 42
Cleaning the powder container................................................................ 42
Repair work........................................................................................................... 43
Periodic checks .................................................................................................... 43
Fault clearance 45
Disposal 47
Introduction........................................................................................................... 47
Requirements on personnel carrying out the work.................................. 47
Disposal regulations................................................................................ 47
Materials.................................................................................................. 47
Spare parts list 49
Ordering spare parts............................................................................................. 49
OptiFlex Pro BN –Spare parts list ....................................................................... 50
OptiFlex Pro BN –Spare parts............................................................................. 51
Stirrer hopper........................................................................................................ 52
Stirrer hopper –Spare parts................................................................................. 53
Stirrer drive unit .................................................................................................... 54
Stirrer drive unit –Spare parts.............................................................................. 55
Pneumatic group .................................................................................................. 56

Rev. 01 08/20
OptiFlex Pro BN About these instructions
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5
About these instructions
General information
This operating manual contains all important information which you
require for the working with the OptiFlex Pro BN. 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 Pro BN
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."

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OptiFlex Pro BN Safety
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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 Pro BN
–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.
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 not considered as intended use. The manufacturer
shall not be liable for damage resulting from such use; the user bears
sole responsibility for such actions. Gema Switzerland GmbH must be
consulted prior to any use of this product for any purposes or
substances other than those indicated in our guidelines.
Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of the intended 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 homepage
www.gemapowdercoating.com.
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.

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OptiFlex Pro BN Safety
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9
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.
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.

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Safety OptiFlex Pro BN
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!
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.

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OptiFlex Pro BN Safety
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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. ESD shoes).
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 Pro BN

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OptiFlex Pro BN Product description
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13
Product description
Intended use
This manual coating equipment is intended for electrostatic coating of
objects that must be grounded, using electrically non-conducting powders
(For more on this please also review chapter "Technical Data").
This Electrostatic manual equipment for Boron Nitride with the OptiSelect
Pro GM04 Manual powder gun or OptiGun GA03 Automatic powder gun
is ideally suited for spraying short bursts of fine grained powder with small
powder output volumes.
Fig.
1
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.
Any other use is considered non-compliant. The manufacturer is not
responsible for any incorrect use and the risks associated with such
actions are assumed by the user alone!

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Product description OptiFlex Pro BN
Reasonably foreseeable misuse
–Operation without the proper training
–The use of electrically conducting powders (like metallic or graphite
powders)
–Use with insufficient compressed air quality and grounding
–Use in connection with unauthorized coating devices or components
Structure
Overall view
fig.
2
1 OptiSelect Pro GM04 manual
powder gun or OptiGun GA03
automatic powder gun
2 Frame
3 Hose holder
4 Filter unit
5 Rubber wheel
6 Swivel wheel
7 Stirrer hopper
8 OptiFlow injector
9 Discharge flap
10 Shelf
11 OptiStar CG21 Gun
control unit
12 Gun holder
13 Filler flap
OptiStar 4.0 Gun control unit
All information about the OptiStar 4.0 (Type CG21) manual gun control
unit can found in the documentation for that equipment (enclosed with this
manual)!
OptiFlow injector
All information about the OptiFlow injector will be found in the
corresponding enclosed documentation!

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OptiFlex Pro BN Product description
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15
Powder guns and powder hoses
All information about the OptiSelect Pro GM04 manual powder gun or
OptiGun GA03 automatic gun can be found in the documentation for that
equipment (enclosed with this manual)!
fig.
3
: Powder guns and powder hoses –overview
1 OptiSelect Pro GM04 gun
body
2 OptiGun GA03 gun body
3 Flat jet nozzle
4 Extensions*
5 Angled nozzle –90°
6 Angled nozzle –60°
7 Angled nozzle –45°
9 Powder hose Ø
12.5/9.5 mm, for lengths 6-
12 m
8 Hose connection 9.5 mm
* 300 and 500 mm extensions, special lengths on request
Scope of delivery
–OptiSelect Pro GM04 manual powder gun or OptiGun GA03
automatic gun with gun cable, powder hose, electrode rinsing air
hose and standard nozzle set (For more on this, see the gun
operating manual)
–OptiStar 4.0 Control unit in a metal case with power supply cable
–plug-in OptiFlow injector
–mobile trolley with a gun/hose support
–Powder hopper with stirrer and cover, inclusive mains adaptor for the
stirrer
–Pneumatic hoses for conveying air (red) and fluidizing air (black)
–Operating manual
–Short description

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Product description OptiFlex Pro BN
Typical characteristics –properties of the functions
Processing the powder from the stirrer recipient
The type S manual coating equipment allows for powder to be processed
directly out of the stirrer recipient. Because of the conical shape of the
stirrer recipient, the powder can be used completely (optimum powder
consumption).

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OptiFlex Pro BN Product description
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17
TechnischeDaten
Technical Data
Connectable guns
OptiFlex Pro BN
connectable
OptiSelect Pro Type GM04
yes
OptiSelect type GM03
yes*
OptiGun GA03
yes**
* The PowerBoost functionality is not available.
** with trigger adapter
ATTENTION
The gun control unit may only be used with the specified gun
types!
Electrical data
OptiFlex Pro BN
Nominal input voltage
110-120 / 230-240 VAC
Frequency
50-60 Hz
Fluctuations of the power supply
± 10 %
Overvoltage category
OVC II
Connected load
150 VA
Nominal output voltage (to the gun)
12 V
Nominal output current (to the gun)
1.2 A
Connection and output for vibrator (on
Aux output)
100-240* VAC
max. 100 W
Connection for rinsing function (valve)
24 VDC
max. 3 W
Protection type
IP54
Approvals
II 3 D
* preset country-specific voltage
Pneumatic data
OptiFlex Pro BN
Compressed air connection
8 mm
Input pressure OptiStar
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

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Product description OptiFlex Pro BN
Dimensions
OptiFlex Pro BN
Width
481 mm
Depth
822 mm
Height
1109 mm
Weight
ca. 57 kg
Processible powders
OptiFlex Pro BN
Powder containing Boron Nitride
yes
Metallic powder
no
Graphite powder
no
Enamel powder
no
Environmental conditions
OptiFlex Pro BN
Utilization
in the interior
Height
up to 2 000 m
Temperature range
+5 °C - +40 °C
(+41 °F - +104 °F)
Max. surface temperature
+85 °C (+185 °F)
Maximum relative humidity
80 % for temperatures to 31 °C,
linearly decreasing to 50 %
relative humidity at 40 °C
Environment
not for wet environment
Degree of pollution of the
intended environment
2 (in accordance with DIN EN
61010-1)
Sound pressure level
OptiFlex Pro BN
Normal operation
< 60 dB(A)
The sound pressure level was measured while the unit was in operation;
measurements were taken at the most frequent operator positions and at
a height of 1.7 m from the ground.
The specified value is applicable only for this product itself and does not
take into account external noise sources or cleaning impulses.
The sound pressure level may vary, depending on the product
configuration and space constraints.

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OptiFlex Pro BN Product description
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19
Rating plate
fig.
4

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Product description OptiFlex Pro BN