Gema OptiFlex Pro F Guide

Rev. 00 1017 933 EN
Operating instructions and Spare parts list
Manual equipment
OptiFlex Pro F
Translation of the original operating instructions

Rev. 00 03/19
Documentation OptiFlex Pro F
© 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]

Rev. 00 03/19
OptiFlex Pro F Table of contents
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3
Table of contents
About these instructions 7
General information ................................................................................................7
Keeping the Manual................................................................................................7
Safety symbols (pictograms)...................................................................................7
Structure of Safety Notes...........................................................................8
Presentation of the contents...................................................................................8
Figure references in the text......................................................................8
Safety 9
General information ................................................................................................9
Basic safety instructions .........................................................................................9
Product specific security regulations ....................................................................10
Product description 15
Intended use .........................................................................................................15
Reasonably foreseeable misuse..............................................................16
Structure................................................................................................................16
Overall view..............................................................................................16
Scope of delivery ..................................................................................................17
Typical characteristics –properties of the functions.............................................17
Processing of the powder from the fluidized powder container...............17
Freely rotating head piece .......................................................................17
PowerClean™ module – Option..............................................................17
Technical Data......................................................................................................19
Connectable guns....................................................................................19
Electrical data ..........................................................................................19
Pneumatic data........................................................................................19
Dimensions ..............................................................................................20
Processible powders................................................................................20
Powder output (reference values)............................................................20
Air flow rates............................................................................................21
Environmental conditions.........................................................................21
Sound pressure level...............................................................................22
Rating plate..............................................................................................22
Assembly / Connection 23
Set-up....................................................................................................................23
Assembly guide.....................................................................................................23
Connection instructions.........................................................................................24
Set head piece......................................................................................................25
Start-up 27
Preparation for start-up.........................................................................................27
Basic conditions.......................................................................................27
Initial start-up.........................................................................................................28
Setting the device type..........................................................................................28

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Table of contents OptiFlex Pro F
Operation 29
Operation.............................................................................................................. 29
Select predefined operating mode (Preset mode) .................................. 30
Starting the individual adjustable programs ............................................ 30
Setting powder output and powder cloud................................................ 31
Setting the electrode rinsing air............................................................... 32
Setting the fluidization ............................................................................. 33
Rinsing mode........................................................................................................ 34
Activating the rinsing function.................................................................. 34
Setting the background illumination ..................................................................... 37
Color change ........................................................................................................ 38
General information................................................................................. 38
Decommissioning / Storage 39
Decommissioning................................................................................................. 39
If in disuse for several days..................................................................... 39
Storage conditions................................................................................................ 39
Hazard notes........................................................................................... 39
Type of storage........................................................................................ 39
Storage duration...................................................................................... 39
Space requirements ................................................................................ 39
Physical requirements............................................................................. 40
Maintenance during storage................................................................................. 40
Maintenance schedule............................................................................. 40
Maintenance works.................................................................................. 40
Maintenance / Repairs 41
General information.............................................................................................. 41
Interval.................................................................................................................. 41
Daily maintenance................................................................................... 41
Weekly maintenance............................................................................... 41
If in disuse for several days..................................................................... 42
Gun maintenance.................................................................................... 42
Maintenance of the filter unit................................................................... 42
Cleaning................................................................................................................ 43
Gun cleaning ........................................................................................... 43
Cleaning the powder container................................................................ 44
Repair work........................................................................................................... 44
Periodic checks .................................................................................................... 44
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 F –Spare parts list .......................................................................... 50
OptiFlex Pro F –Spare parts................................................................................ 51
Powder hopper HF05-50 –Spare parts list.......................................................... 52
Powder hopper HF05-50 –Spare parts ............................................................... 53
Pneumatic group .................................................................................................. 54
PowerClean module set**..................................................................................... 55

Rev. 00 03/19
OptiFlex Pro F Table of contents

5

Rev. 00 03/19
OptiFlex Pro F About these instructions

7
About these instructions
General information
This operating manual contains all important information which you
require for the working with the OptiFlex Pro 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.

Rev. 00 03/19
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
About these instructions OptiFlex Pro 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 03/19
OptiFlex Pro F Safety

9
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.

Rev. 00 03/19
10

Safety OptiFlex Pro 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.