Gema OptiFlex Pro F Guide

Rev. 00 1017 934 EN
Operating instructions and Spare parts list
Manual equipment
OptiFlex Pro F Spray
Translation of the original operating instructions

Rev. 00 03/19
Documentation OptiFlex Pro F Spray
© 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 F Spray 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
Versions...................................................................................................16
Reasonably foreseeable misuse..............................................................16
Structure................................................................................................................17
Overall view..............................................................................................17
Scope of delivery ..................................................................................................18
Typical characteristics –properties of the functions.............................................18
Processing of the powder from the fluidized powder container...............18
Freely rotating head piece .......................................................................18
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............................................................................................20
Environmental conditions.........................................................................21
Sound pressure level...............................................................................21
Rating plate..............................................................................................21
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 Spray
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 spraying air............................................................................ 32
Setting the electrode rinsing air............................................................... 33
Cleaning mode ..................................................................................................... 34
Cleaning programs.................................................................................. 34
Activating the cleaning function............................................................... 35
Pinch valve diagnostic............................................................................. 36
Setting the background illumination ..................................................................... 37
Color change ........................................................................................................ 38
General information................................................................................. 38
Decommissioning / Storage 41
Shutdown.............................................................................................................. 41
If in disuse for several days..................................................................... 41
Storage conditions................................................................................................ 41
Hazard notes........................................................................................... 41
Type of storage........................................................................................ 41
Storage duration...................................................................................... 41
Space requirements ................................................................................ 41
Physical requirements............................................................................. 42
Maintenance during storage................................................................................. 42
Maintenance schedule............................................................................. 42
Maintenance works.................................................................................. 42
Maintenance / Repairs 43
General information.............................................................................................. 43
Interval.................................................................................................................. 43
Daily maintenance................................................................................... 43
Weekly maintenance............................................................................... 43
If in disuse for several days..................................................................... 44
Gun maintenance.................................................................................... 44
Maintenance of the filter unit................................................................... 44
Cleaning................................................................................................................ 45
Gun cleaning ........................................................................................... 45
Cleaning the powder container................................................................ 46
Repair work........................................................................................................... 46
Periodic checks .................................................................................................... 46
Fault clearance 47
Disposal 49
Introduction........................................................................................................... 49
Requirements on personnel carrying out the work.................................. 49
Disposal regulations................................................................................ 49
Materials.................................................................................................. 49
Spare parts list 51
Ordering spare parts............................................................................................. 51
OptiFlex Pro F Spray –Spare parts list................................................................ 52
OptiFlex Pro F Spray –Spare parts..................................................................... 53
Powder hopper HF05-50 Spray –Spare parts list................................................ 54
Powder hopper HF05-50 Spray –Spare parts..................................................... 55

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OptiFlex Pro F Spray Table of contents
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5
Diffuser (OptiSelect)..............................................................................................56
Pneumatic group...................................................................................................57

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OptiFlex Pro F Spray 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 Spray. 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 F Spray
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 F Spray 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.

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Safety OptiFlex Pro F Spray
–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.

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OptiFlex Pro F Spray Safety
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11
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 Pro F Spray
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!

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OptiFlex Pro F Spray Safety
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13
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 Pro F Spray

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OptiFlex Pro F Spray Product description

15
Product description
Intended use
This Manual coating equipment is for use with organic powders coating
electrostatically grounded objects.
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 F Spray
Versions
The manual coating equipment is available in different versions and
covers a broad application range.
This manual unit is the right solution for coatings that require a constant
powder output or high film builds. With a powder output of up to 600 g/min
and an extremely high efficiency best coating results are achieved.
Application
Precise powder transport
Option
I
Ia (Extension Kit)
Number of guns
1
1+1
Number of pumps
1
1+1
Powder output
1x 50-300 g/min
2x 50-300 g/min
Application
Hot coating
Option
II
IIa (Extension Kit)
Number of guns
1
1+1
Number of pumps
2
2+2
Powder output
1x 100-600 g/min
2x 100-600 g/min
Reasonably foreseeable misuse
–Operation without the proper training

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OptiFlex Pro F Spray Product description
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17
–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
2 Frame
3 OptiSpray Dense phase
pump
4 Filter unit
5 Rubber wheel
6 Swivel wheel
7 Fluidized powder hopper
8 Powder suction hose
9 AirMover
10 Shelf
11 OptiStar CG23-P Gun
control unit
12 Gun holder
OptiSelect Pro GM04 manual powder gun
All information about the OptiSelect Pro GM04 manual powder gun can
be found in the documentation for that equipment (enclosed with this
manual)!
OptiStar 4.0 Gun control unit
All information about the OptiStar 4.0 (Type CG23-P) manual gun control
unit can found in the documentation for that equipment (enclosed with this
manual)!
OptiSpray AP01 Application Pump
All information about the OptiSpray AP01 application pump will be found
in the corresponding enclosed documentation!

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Product description OptiFlex Pro F Spray
Scope of delivery
–OptiSelect Pro GM04 manual powder gun with gun cable, powder
hose, electrode rinsing air hose and standard nozzle set (For more
on this, see the operating manual for the OptiSelect Pro GM04
manual powder gun)
–Diffuser
–OptiStar 4.0 Control unit in a metal case with power supply cable
–OptiSpray AP01Application Pump
–mobile trolley with a gun/hose support
–Fluidized powder hopper
–Pneumatic hoses for transport air (blue), spraying air (black), pinch
valve air (green) and fluidizing air (black)
–Operating manual
–Short description
Typical characteristics –properties of the functions
Processing of the powder from the fluidized
powder container
The OptiFlex 2 F manual coating equipment processes powder from the
fluidized powder container.
Freely rotating head piece
The manual coating equipment features a rotating and lockable head
piece for more ergonomic operation and configuration (in steps of 45°)
fig.
3

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OptiFlex Pro F Spray Product description
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19
TechnischeDaten
Technical Data
Connectable guns
OptiStar
connectable
OptiSelect Pro Type GM04
yes, with diffuser
OptiSelect type GM03
yes*, with diffuser
* The PowderBoost functionality is not available.
ATTENTION
The gun control unit may only be used with the specified gun types!
Electrical data
OptiFlex Pro F Spray
Nominal input voltage
100-240* VAC
Frequency
50-60 Hz
Fluctuations of the power supply
± 10 %
Overvoltage category
OVC II
Connected load
140 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 F Spray
Compressed air connection
8 mm
Max. input pressure
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 F Spray
Dimensions
OptiFlex Pro F Spray
Width
481 mm
Depth
822 mm
Height
1109 mm
Weight
ca. 50 kg
Processible powders
OptiFlex Pro F Spray
Plastic powder
yes
Metallic powder
yes
Enamel powder
no
Powder output (reference values)
OptiFlex Pro F Spray
Conveying hose till 20 m –internal Ø 7 mm
Suction hose max. 1.5 m –internal Ø 4.5 mm
50-300 g/min
Air flow rates
The total air consists of transport air and supplementary air, in relation to
the selected powder quantity (in %). As a result the total air volume is
maintained constant.
OptiFlex Pro F Spray
Range
Factory
setting
Flow rate –fluidizing air:
–Device type B
0-1.0 Nm³/h
0.1 Nm³/h
–Device type F (without AirMover
air requirements)
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
–Transport air flow rate
0-5.5 Nm³/h
–Spraying air flow rate
0-5.5 Nm³/h
The max. total air consumption during the coating operation is
< 5,5 Nm³/h:
–Total air = 5 Nm³/h (Transport air + Spraying 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 for device
type F).
–These values apply for an internal control pressure of 5.5 bar!