ITW Gema OptiFlex 2 C Guide

En
Operating instructions and spare parts list
Manual coating equipment
OptiFlex 2 C
Translation of the ori
g
inal o
p
eratin
g
instructions

V 06/11
Documentation OptiFlex 2 C
© Copyright 2010 ITW Gema 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 ITW Gema GmbH.
OptiFlex, OptiTronic, OptiGun, EasyTronic, OptiSelect, OptiFlow and
SuperCorona are registered trademarks of ITW Gema GmbH.
OptiMatic, OptiMove, OptiMaster, OptiPlus, PowerClean, Precise Charge
Control (PCC), OptiSpray, MultiTronic and Gematic are trademarks of
ITW Gema 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. ITW Gema
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.
Printed in Switzerland
ITW Gema GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone: [phone]
Fax.: [phone]
E-Mail: [email protected]
Homepage: www.itwgema.ch

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OptiFlex 2 C Table of contents 1
Table of contents
General safety regulations 3
Safety symbols (pictograms) ................................................................................... 3
Conformity of use .................................................................................................... 8
Product-specific safety measures ........................................................................... 8
OptiFlex 2 C Manual coating equipment .................................................... 8
About this manual 9
General information ................................................................................................ 9
Product description 11
Field of application ................................................................................................ 11
Utilization .................................................................................................. 11
Reasonably foreseeable misuse .............................................................. 12
Technical data ....................................................................................................... 12
Connectable guns .................................................................................... 12
Air flow rates ............................................................................................ 12
Electrical data .......................................................................................... 13
Pneumatic data ........................................................................................ 13
Dimensions .............................................................................................. 13
Processible powders ................................................................................ 13
Design and function .............................................................................................. 14
General view ............................................................................................ 14
Scope of delivery .................................................................................................. 15
OptiFlex 2 C ............................................................................................. 15
Typical properties - Characteristics of the functions ............................................. 15
Processing the powder from the application cup ..................................... 15
Start-up 17
Preparation for start-up ......................................................................................... 17
Basic conditions ....................................................................................... 17
Set-up .................................................................................................................... 17
Mounting instructions ............................................................................................ 18
Connection instructions ......................................................................................... 18
Initial start-up 21
Setting the device type .......................................................................................... 22
Operation .............................................................................................................. 23
Coating ..................................................................................................... 23
Setting the background illumination ......................................................... 26
Color change ......................................................................................................... 26
General information ................................................................................. 26
Shutdown .............................................................................................................. 27
Cleaning and maintenance 29
Daily maintenance ................................................................................................ 29

V 06/11
2 Table of contents OptiFlex 2 C
Weekly maintenance ............................................................................................ 29
If in disuse for several days .................................................................................. 29
Cleaning ................................................................................................................ 30
Cleaning the application cup ................................................................... 30
Cleaning the OptiFlex 2 GM03 manual powder gun ............................... 30
Maintenance and cleaning of the filter unit ........................................................... 31
Replacing the filter element ..................................................................... 31
Troubleshooting 33
General information .............................................................................................. 33
Spare parts list 35
Ordering spare parts ............................................................................................. 35
OptiFlex 2 C manual coating equipment - Spare Parts List ................................. 36
OptiFlex 2 C manual coating equipment - Spare Parts ........................................ 37
OptiFlex 2 C - Pneumatic group ........................................................................... 38

V 06/11
OptiFlex 2 C General safety regulations 3
General safety regulations
This chapter sets out the fundamental safety regulations that must be
followed by the user and third parties using OptiFlex 2 C manual coating
equipment.
These safety regulations must be read and understood in full before the
OptiFlex 2 C is put into operation.
Safety symbols (pictograms)
The following warnings with their meanings can be found in the ITW
Gema operating instructions. The general safety precautions must also
be followed as well as the regulations in the operating instructions.
DANGER!
danger due to live electricity or moving parts. Possible consequences:
death or serious injury
WARNING!
improper use of the equipment could damage the machine or cause it to
malfunction. Possible consequences: minor injuries or damage to
equipment
INFORMATION!
Useful tips and other information

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4 General safety regulations OptiFlex 2 C
The OptiFlex 2 C manual coating equipment is state of the art equipment
that conforms to the recognized technical safety regulations and is
designed for normal powder coating applications.
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. ITW Gema GmbH must be consulted
before OptiFlex 2 C manual coating equipment is used for any other
purposes or substances beyond those indicated here.
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.itwgema.ch.
Start-up is forbidden until it has been established that the OptiFlex 2 C
manual coating equipment has been set up and wired according to the
EU guidelines for machinery.
Unauthorized modifications to the OptiFlex 2 C Manual coating
equipment exempt the manufacturer from any liability from resulting
damages or accidents.
The operator must ensure that all users have received 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.
General
dangers
General
information

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OptiFlex 2 C General safety regulations 5
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 ITW Gema spare parts should be used!
Repairs must only be carried out by specialists or by authorized ITW
Gema service centers. Unauthorized conversions and modifications can
lead to injuries and damage to the equipment and invalidate the ITW
Gema GmbH guarantee.
The connecting cables between the control unit and the spray gun must
be installed so as to eliminate the possibility of damage 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 powder coating equipment may not be switched on until the booth is
in operation. If the booth stops, the powder coating device must switch off
too.
The control units for the spray guns must be installed and used in zone
22. Spray guns are allowed in zone 21.
Only original ITW Gema OEM parts are guaranteed to maintain the
explosion protection rating. If damages occur related to the use of spare
parts from other manufacturers, all relevant warranty or compensation
claims are 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 greater 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.
The safety devices may not 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.
Electrical
danger
Explosion hazard

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6 General safety regulations OptiFlex 2 C
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 designed for this purpose.
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
All electrically conductive parts found within 5 meters around each booth
opening, and in particularly the objects to be coated, must 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 igniting fire are forbidden in the entire vicinity of the system!
No work that could potentially produce sparks is allowed!
Slip hazard
Observe the
grounding
regulations
Fire and smoke
prohibition

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OptiFlex 2 C General safety regulations 7
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 can lead to unnecessary releases and/or
disconnections by safety devices.
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 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.
These general safety regulations must
be read and understood in all cases
prior to start-up!
The stay for persons
with cardiac
pacemakers is
forbidden
Photographing with
flashlight is
forbidden
Disconnect from
mains before
maintenance works
take place

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8 General safety regulations OptiFlex 2 C
Conformity of use
1. The OptiFlex 2 C manual coating equipment is state of the art
equipment that conforms to the recognized technical safety
regulations and is designed for normal powder coating
applications.
2. 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. ITW Gema GmbH
must be consulted before OptiFlex 2 C manual coating
equipment is used for any other purposes or substances beyond
those indicated here.
3. Observance of the operating, service and maintenance
instructions specified by the manufacturer is also part of
conformity of use. The OptiFlex 2 C manual coating equipment
should only be used, maintained and started up by trained
personnel informed and familiar with the possible hazards
involved.
4. Start-up (i.e. operation of its intended use) is not allowed until it
has been established that the OptiFlex 2 C manual coating
equipment has been installed and wired according to the EU
Machinery Directive (2006/42/EC). EN 60204-1 (machine safety)
must also be observed.
5. Unauthorized modifications to the OptiFlex 2 C manual coating
equipment exempt the manufacturer from any liability from
resulting damage.
6. The relevant accident prevention regulations, as well as other
generally recognized safety regulations, occupational health and
structural regulations are to be observed.
7. Furthermore, the country-specific safety regulations also must be
observed.
Product-specific safety measures
- Installation work performed by the customer must be carried
out according to local regulations.
- All components must be grounded according to the local
regulations before start-up.
OptiFlex 2 C Manual coating equipment
The OptiFlex 2 C manual coating equipment 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.
Note:
For further security information, see the more detailed ITW Gema
safety regulations!

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OptiFlex 2 C About this manual 9
About this manual
General information
This operating manual contains all important information required to work
with the OptiFlex 2 COptiFlex 2 C-en.doc manual coating equipment. It
will safely guide you through the start-up process and give you
references and tips for the optimal use of your new powder coating
system.
Information about the functionality of the individual system components -
booth, gun control unit, manual gun or powder injector - should be
referenced to their enclosed corresponding documents.

V 06/11
OptiFlex 2 C Product description 11
Product description
Field of application
The OptiFlex 2 C (with application cup) manual coating equipment is
exclusively intended for electrostatic coating using organic powders (For
more on this please also review chapter "Technical Data").
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!
For a better understanding of the interrelationships in powder coating, it
is recommended that the operating instructions for all other components
be read as well, so as to be familiar with their functions too!
OptiFlex 2 C Manual coating equipment
Utilization
The electrostatic OptiFlex 2 C manual coating equipment with the
OptiFlex 2 GM03 manual powder gun is ideally suited for manual coating
of objects.

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12 Product description OptiFlex 2 C
Reasonably foreseeable misuse
- Operation without the proper training
- Use with insufficient compressed air quality and grounding
- Use in connection with unauthorized coating devices or
components
Technical data
Connectable guns
OptiFlex 2 C connectable
OptiFlex 2 GM03 yes
Warning:
The OptiFlex 2 C manual coating equipment can only be used with
the specified gun type!
Air flow rates
The total air consists of conveying air and supplementary air, in relation
to the selected powder quantity (in %). As a result the total air volume is
maintained constant.
OptiFlex 2 C Range Factory
setting
Flow rate - fluidizing air
- OptiFlex C 0-5.0 Nm³/h 1.0 Nm³/h
Electrode rinsing air flow rate 0-3.0 Nm³/h 0.1 Nm³/h
Flow rate total air (at 5.5 bar) 1.8-6.5 Nm³/h
Note:
The total air consumption for the device is determined based on the
3 configured air values.
These values apply for an internal control pressure of 5.5 bar!

V 06/11
OptiFlex 2 C Product description 13
Electrical data
OptiFlex 2 C
Nominal input voltage 100-240 VAC
Frequency 50 -60 Hz
Connected load 40 VA
Nominal output voltage (to the gun) eff.10 V
Nominal output current (to the gun) max. 1.2 A
Connection for rinsing function (valve) 24 VDC
max. 3 W
Temperature range 0°C - +40°C
(+32°F - +104°F)
Max. surface temperature 100 °C (+212 °F)
Approvals II 3 D IP54 100 °C
Pneumatic data
OptiFlex 2 C
Max. input pressure 10 bar
Min. input pressure 6 bar
Input pressure (Dynamic based on pressure
regulator setting) 5.5 bar / 80 psi
Max. water vapor content of the compressed
air 1.3 g/m³
Max. oil vapor content of the compressed air 0.1 mg/m³
Max. compressed air consumption 11 Nm³/h
Dimensions
OptiFlex 2 C
Width 444 mm
Depth 310 mm
Height 428 mm
Weight 12 kg
Processible powders
OptiFlex 2 C
Plastic powder yes
Metallic powder yes
Enamel powder no

V 06/11
14 Product description OptiFlex 2 C
Design and function
General view
OptiFlex 2 C manual coating equipment - Setup
1 OptiFlex 2 CG09 control unit 10 Filter unit
2 OptiFlex 2 GM03 manual powder gun 11 Gun holder
3 Application cup 14 Shelf
4 Base
OptiFlex 2 GM03 manual powder gun
All information about the OptiFlex 2 GM03 manual powder gun can be
found in the documentation for that equipment (enclosed with this
manual)!
OptiFlex 2 CG09 control unit
All information about the OptiFlex 2 CG09 manual gun control unit can
found in the documentation for that equipment (enclosed with this
manual)!
Application cup
All information about the application cup will be found in the
corresponding, enclosed documentation!
11
2
1
10
4 3
14

V 06/11
OptiFlex 2 C Product description 15
Scope of delivery
OptiFlex 2 C
- OptiFlex 2 CG09 control unit in a metal case with power
supply cable
- Base with column and filter unit
- Application cup, complete with pneumatic connection to
the control unit
- OptiFlex 2 GM03 manual powder gun with gun cable,
powder hose, rinsing air hose and standard nozzle set
(For more on this, see the operating manual for the
OptiFlex 2 GM03 manual powder gun)
- Operating manual
- Short instructions
Typical properties - Characteristics of the functions
Processing the powder from the application cup
The OptiFlex 2 C manual coating equipment processes powder from the
application cup.

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OptiFlex 2 C Start-up 17
Start-up
Preparation for start-up
Basic conditions
When starting up the OptiFlex 2 C manual coating unit, the following
general conditions impacting the coating results must be taken into
consideration:
- Manual coating equipment is set up properly
- Gun control unit correctly connected
- Gun correctly connected
- Corresponding power and compressed air supply available
- Powder preparation and powder quality
Set-up
The OptiFlex 2 C manual coating equipment should always be set up
vertically on a flat surface.
WARNING
The manual coating equipment must not under any circumstances
be set up near a heat source (such as an enameling furnace) or an
electromagnetic source (such as a control cabinet).

V 06/11
18 Start-up OptiFlex 2 C
Mounting instructions
The OptiFlex 2 C manual coating equipment must be set up in
accordance with the setup and connecting instructions (included with
delivery).
OptiFlex 2 C Manual coating equipment
Connection instructions
Connection instructions - overview
The OptiFlex 2 C manual coating equipment must be connected in
accordance with the setup and connection instructions (Please also
review the operating instructions for the OptiFlex 2 CG09 manual gun
control unit).
Filter unit
Gun
Application cup