Gema OptiFlex Pro BN User manual

Rev. 00 1024 620 EN
Quick reference guide
Manual equipment
OptiFlex Pro BN
The complete operating instructions with detailed information
and spare parts lists can also be found at:
https://docs.gemapowdercoating.com/9721f6c169
Translation of the original operating instructions

Rev. 00 07/23
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, OptiStar, OptiStar All-in-One and PowerBoost 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) and
SuperCorona are registered 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 information regarding patents, see
www.gemapowdercoating.com/patents or
www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone: [phone]
Email: [email protected]

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OptiFlex Pro BN Table of contents
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3
Table of contents
Other applicable documents 4
Safety 5
General information ................................................................................................5
Basic safety instructions .........................................................................................5
Product specific security regulations ......................................................................6
Start-up 11
Initial start-up.........................................................................................................11
Operation 13
Operation ..............................................................................................................13
Maintenance / Repairs 17
Cleaning................................................................................................................17
Replacing the insert sleeve...................................................................................21
Spare parts list 23
Ordering spare parts.............................................................................................23
OptiFlex Pro BN –Spare parts list........................................................................24
EC Declaration of Conformity ...............................................................................32

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Table of contents OptiFlex Pro BN
Other applicable documents
In addition to the information contained in this manual, the following
operating instructions and spare parts lists for the individual components
must also be observed:
OptiStar CG21 Gun control unit
https://docs.gemapowdercoating.com/880b384645
OptiGun GA03 automatic powder gun
https://docs.gemapowdercoating.com/a1f01efb8d
OptiSelect Pro GM04 manual powder gun
https://docs.gemapowdercoating.com/7729cd9516
OptiFlow IG06-BN injector
https://docs.gemapowdercoating.com/9db2d628e2

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5
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.
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 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.

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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.
Danger due to compressed air
Uncontrolled release of strong compressed air containing powder can
cause hearing, eye and skin damage.

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Safety OptiFlex Pro BN
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 of persons with active implants
The stay for persons
with active implants is
forbidden
In general, all persons with active implants (e.g. with cardiac
pacemakers, neurostimulators, insulin pumps, etc.) must not be in
areas where strong high voltage and electromagnetic fields are
generated. Persons with active implants should not enter areas with
powder spraying installations in operation!

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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 and secure against restart before the machines
are opened for maintenance or repair!
Verify by means of a voltmeter that the parts are deenergized!
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 equipment (e.g. hearing, eye,
respiratory protection etc.).
A dust mask corresponding to filter class FFP2 or N95 at minimum
must be worn during any cleaning work, as powder can enter the
respiratory tract in an uncontrolled manner and cause breathing
difficulties.
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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Start-up
Initial start-up
If a malfunction occurs, see the troubleshooting guide, as well as
the gun control unit operating manual!
fig.
1
The remainder of the start-up procedure for the gun is explicitly
described in the operating instructions for the OptiStar CGxx
manual powder gun control unit (chapter "Initial start-up" and
"Daily start-up")!

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Start-up OptiFlex Pro BN

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Operation
WARNING
Holding the gun incorrectly
During the coating process, the gun can discharge along the body
of the coater if not held using its intended handle, which has been
grounded.
►Always hold gun only by the handle!
►Do not touch any other parts of the gun!
Bedienung
Operation
CAUTION
Large dust formation possible!
If the manual equipment is not being used for coating in
conjunction with a sufficiently powerful suction unit, then the
stirred-up dust from the coating powder can cause respiratory
issues or cause a slippage/falling hazard.
►The manual equipment may only be operated in conjunction with
a sufficiently powerful suction unit (such as Gema Classic Open
booth).
1. Fill the stirrer hopper with powder
a) Open the hinged flap of the stirrer hopper cover
CAUTION
Hand injury!
If the cover to the agitator unit is opened, then this can fall shut
again during inattentive handling. Fingers or hands in the
cover/container zone can be crushed.
►Observe the cover.
b) Fill in the coating powder in the stirrer recipient. Maximum filling
level of the powder is marked on the inside of the recipient
(useful capacity approx. 18,5 dm³)
Check whether the discharge flap is closed and not just ajar.

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Operation OptiFlex Pro BN
c) Close the hinged flap of the stirrer recipient cover
d) The stirrer can be put into operation by pressing manually the
button on the cover when filling/emptying
2. Set coating parameters
Select predefined operating mode (Preset mode)
1. Turn on the gun control unit with the ON key
2. Press the corresponding application key.
The arrow above the desired button lights up.
The pre-defined application modes have preset values for high
voltage and spray current:
Application mode
Preset kV
Preset µA
flat parts
100
100
complicated parts
100
22
overcoat
100
10
3. The air values for total air, powder output and electrode rinsing air
can be individually defined and are saved in the programs.
Starting the individual adjustable programs
1. Turn on the gun control unit with the ON key
2. Press the program key
3. Select the desired program (01-20)
Program 20 active
4. Change the coating parameters as required
Programs 01-20 are preset at the factory but can be modified at
any time, after which they are automatically stored.

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Description
Presetting
Powder output
60 %
(50% for device type CF)
Total air
4.0 Nm³/h
(2.5 Nm³/h for device type CF)
High voltage
80 kV
Spray current
20 µA
Electrode rinsing air
0.1 Nm³/h
Fluidizing air
1.0 Nm³/h (for device type F)
0.1 Nm³/h (for device type B and S)
Setting powder output and powder cloud
The powder output depends on the selected powder output (in %), and
the powder cloud on the selected total air volume.
As a factory default value, a powder rate of 50% and a total air
volume of 4 Nm³/h are recommended.
–If values are entered that the gun control unit cannot implement,
then the operator is informed of this by a blinking in the relevant
display and a temporary error message!
Setting the total air volume
1.
Adjust the total air volume on the gun control unit with the T3/T4
keys
–Adjust the total air volume according to the corresponding
coating requests
correct powder cloud
too little total air
Setting the powder output
1. OR

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Operation OptiFlex Pro BN
much powder
little powder
Adjust the powder output volume (e.g. according to the desired
coating thickness)
–Factory default setting of 50% is recommended for initial
operation. The total air volume is thereby kept constant
automatically by the control unit.
To achieve maximum efficiency, we recommend avoided an
overly high powder volume where possible!
2. Check fluidization of the powder in the powder container
3. Point the gun into the booth, switch the gun on and visually check
the powder output
Setting the electrode rinsing air
1. Press the key.
The second display level will be shown.
2.
Adjust the correct electrode rinsing air according to the applied
nozzles (deflector plate, flat jet nozzle)
≈ 0.1 Nm³/h
≈ 0.5 Nm³/h
too much electrode rinsing air
3. If in this display level is no operation for 3 seconds, the first display
level is switched over independently.

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Maintenance / Repairs
Reinigung
Cleaning
ATTENTION
Any unauthorized modifications and alterations to the product are
not permitted for safety reasons and exclude the manufacturer’s
liability for any resulting damage!
Regular and conscientious cleaning and maintenance increase
the service life of the product and ensure consistent high coating
quality!
–The parts to be replaced during maintenance work are available
as spare parts. These parts can be found in the appropriate
spare parts list!
CAUTION
Large dust formation possible!
If no dust mask or one of an insufficient filter class is worn when
cleaning the product, then the dust that is stirred up from the
coating powder can cause respiratory problems.
►The ventilation system must be turned on for all cleaning work.
►A dust mask corresponding to filter class FFP2 or N95 at
minimum must be worn during any cleaning work.
Gun cleaning
ATTENTION
Impermissible solvents
The following solvents may not be used to clean the gun:
►Ethylene chloride, acetone, ethyl acetate, methyl ethyl ketone,
methylene chloride, premium gasoline, turpentine,
tetrachloromethane, toluene, trichloroethylene, xylene!

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Maintenance / Repairs OptiFlex Pro BN
Only cleaning agents with a flash point of a least 5 Kelvin above
the ambient temperature, or cleaning places with technical
ventilation are allowed!
Before cleaning the powder gun, switch off the control unit. The
compressed air used for cleaning must be free of oil and water!
Daily:
1. Blow off the outside of the gun and wipe, clean etc.
Weekly:
2. Remove powder hose
3. Remove the spray nozzle from the gun and clean it with compressed
air
4. Blow through the gun with compressed air, beginning from the
connection in flow direction
5. Clean the integrated gun tube with the brush supplied if necessary
6. Blow through the gun with compressed air again
7. Clean the powder hose
8. Reassemble the gun and connect it
Cleaning the powder container
1. Place an empty container under the discharge flap.
2. Open the discharge flap by pushing the lever towards the column.
WARNING
Hand injury!
When opening/closing the discharge flap, fingers caught between
the flap/injector bracket and lever can be severely crushed!
►Open/close the discharge flap carefully.
3. Press the Push button on the powder hopper cover and continue to
hold it down.
–The powder then empties into the container.
4. Remove the injector, and the plug covering the second injector hole
5. Clean the injector and the injector seat hole (see therefore the
injector user manual)
WARNING
Danger of accident
When the stirrer is operating, fingers can be severely crushed
between the flap/injector bracket!
►Never put fingers or any other objects into the injector seat hole at
the bottom of the powder hopper!
6. Remove the cover (take care not to damage the stirrer arm)

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7. Blow off with compressed air the hopper, cover and stirrer arm, and
wipe with a clean, dry brush, and a clean cloth.
8. Carefully close the cover again (taking care of the stirrer arm), and fit
the injector, and hoses.
–The coating equipment is now ready for operation.
Do not refill the powder hopper until just before the next use!
Cleaning the injector
ATTENTION
Injector parts may be damaged during the cleaning process.
►Clean individual parts using compressed air; if necessary,
dissolve any sintering in nitro thinner.
►Do not use acetone, do not scrape!
Cleaning intensity depends of the powder used. For optimal cleaning
results, we recommend dismantling the entire injector into its dismantable
components.
1. Remove the injector
2. Remove the powder hose from the hose connection
3. Clean the hose connection with compressed air which is free of oil
and water, and check for wear
4. Clean the injector body with compressed air which is free of oil and
water.
–Any contamination can be seen through the opening of the
hopper fitting
5. If there is heavy contamination, dismantle the injector
ATTENTION
Individual parts may be damaged during the cleaning process.
►Please dismantle carefully to avoid damages!
►Remove the powder stop units (1 and 6) with the correct sized
spanner.
6. Reinsert the injector and fix it

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Fig.
2
1 Powder stop unit
(supplementary air)
2 Powder hose quick release
connection
3 Powder hopper connection
4 Injector body
6 Powder stop unit
(conveying air)
Cleaning the powder stop units
ATTENTION
Damage or loss of function!
Parts of the powder stop unit may be damaged during the
dismantling process.
►Blow off the filter elements from the inside to the outside!
►Do not immerse the filter elements in fluidities or solvents!!!
►Never remove the supporting ring!
Fig.
3
1 Connection/plug
2 O-ring
3 Filter element
3.1 Supporting ring