Manual coating equipment OptiFlex 2 W
Contents
1. 9 Adjust the powder output volume e g according to the desired coating thickness HOOH em much powder little powder Note o To achieve maximum efficiency We recommend avoided an overly 1 high powder volume where possible The standard setting of 50 and a total air volume of 4 Nm3 h is recommended at the start The total air volume is thereby kept constant automatically by the control unit If values are entered that the equipment cannot implement then the operator is informed of this by a blinking in the relevant display and a temporary error message 10 Setting the electrode rinsing air sel a Press the key The second display level will be shown A ge Di BE OptiFlex 2 W e 21 Gema 22 e V 03 13 0 1 Nm h g K approx 0 5 Nm h 11 Setting the fluidization too much electrode rinsing air sel a Press the key The second display level will be shown ri c Check the powder fluidization in the powder container The powder fluidization in the powder containers depends on the powder characteristics the humidity and the ambient air temperature Fluidizing and vibration start by switching on the control unit WARNING If the ventilation has been incorrectly adjusted then the coating powder can create a dust cloud capable of causing respiratory problems Ensure proper setting of ventilation 12 Point the gun into the booth not at the object to be coated press the gun tri2. S17 Application mode for recoating parts already coated is activated 40 e OptiFlex 2 W Wi Gema sTwvGema sel n S3 S6 S19 S13 on off Displays and LEDs Level 2 Designation pe en Electrode rinsing air display in Nm h Se Fluidizing air display in Mme Activation of vibration fluidization Display illumination 0 8 OptiFlex 2 W e Ai Gema Wi Input keys and switches Tru Gema T1 T4 PAI T16 T17 T13 T14 T15 Input keys and switches Designation Function T9 Select Switch between display levels Switching on and off the fluidization OptiFlex F Switch on off for vibration and fluidization OptiFlex B Switching on and off the stirrer OptiFlex S to system parameter mode Press for at least 5 SECS Gs Preset mode for flat parts fixed values Preset mode for complex parts with depressions fixed values Preset mode for overcoating parts already coated fixed values T16 T17 Power switch On Off 42 OptiFlex 2 W Wi Gema Troubleshooting Error diagnosis of the software General information The OptiFlex 2 CG09 manual gun control unit is constantly monitored for correct functionality If the equipment software determines a fault an error message is indicated with a help code Following is monitored High voltage technology Pneumatic system Power supply Help codes The error diagnosis codes help codes are shown in
3. F Max surface temperature 100 C 212 F Connection for rinsing function valve Temperature range OptiFlex 2 W KO O O a Gema 12 e V 03 13 Pneumatic data Input pressure Dynamic based on pressure 5 5 bar 80 psi regulator setting gt water vapor content of the compressed 1 3 g m Max oil vapor content of the compressed air 0 1 mg m Max compressed air consumption 8 Nm h Dimensions Plastic powder Metallic powder Powder output guide values General conditions for the OptiFlow Injector FPowderhoselensthim e 7 Correction value CO Powder output zeroing adjustment OptiFlex 2 W Wi Gema Guide values for OptiFlex 2 CG09 with the OptiFlow IG06 injector All values in these tables are guide values Differing environmental conditions wear and different powder types can affect the table values 3 Nm h 4 Nm h 5 Nm h Powder output g min Total air Powder output 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 CGO9 Range ON setting Flow rate fluidizing air OptiFlex F without AirMover air requirements 0 5 0 Nm h 1 0 Nm h Electrode rinsing air flow rate 0 3 0 Nm h 0 1 Nm h Flow rate total air at 5 5 bar 1 8 6 5 Nm h Note A The total air consumption for the device is determ
4. OptiFlex 2 W manual coating equipment Spare Parts OptiFlex 2 W manual coating equipment Spare Parts OptiFlex 2 W e 37 Gema W i OptiFlex 2 W Pneumatic group Pneumatic group complete 1008 889 1 Filter cartridge 20 um 1008 239 Wearing part OptiFlex 2 W Pneumatic group 38 e OptiFlex 2 W Wi Gema OptiFlex 2 CG09 Structure OptiFlex 2 W Note For further information see the corresponding operating manual which can be found on the accompanying CD General view La bd ei Gata td La 1 Front plate with control and 3 Back panel with interfaces display elements 2 Enclosure e 39 Gema Wi Operating elements Display and input buttons Note O For easier operation of the control unit the preset and actual values 1 are distributed across several levels The sel key is used to switch between the levels If no controls are used within 6 s the device automatically returns to level 1 A1 A4 S1 ld A Leg lt 3 cr sel CH LI Displays Level 1 Designation Function Display of actual values preset values and system A1 A4 parameters Display of program numbers error diagnosis codes and status information Powder output display in s4 Total air volume display in Nm h High voltage display in kV s0 Spraying current display in HA S4 Fluidizing display in Nm h ee Electrode rinsing air display in Nm h
5. flames are forbidden in the entire plant area No work that could potentially produce sparks is allowed OptiFlex 2 W The stay for persons with cardiac pacemakers is forbidden Photographing with flashlight is forbidden Disconnect from mains before maintenance works take place Wi Gema 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 OptiFlex 2 W prior to start up Gema V 03 13 e Note
6. light to dark OptiFlex 2 W e 25 Gema 26 e V 03 13 Remove and clean the nozzle purge gun using air 15 Separate fluidized air cable 16 Remove cover purge with compressed air and clean with a clean dry brush and cloth 17 Clean suction intake pipe 18 Empty remaining powder into a container 19 Vacuum up container and in particular the bottom 20 Clean container with a cloth 21 Reconstruct the powder container 22 Fill with new powder OptiFlex 2 W Wi Gema 28 30 Shutdown 1 Release gun trigger 2 Switch off the control unit o Note The adjustments for high voltage powder output electrode rinsing air and fluidizing remain stored If in disuse for several days Separate from power mains 2 Clean the coating equipment see the corresponding operating manual 3 Turn off the compressed air main supply OptiFlex 2 W e 27 Wi Gema Cleaning and maintenance the OptiFlex 2 W manual coating equipment and provides for a longer continuous coating quality The parts which are to be replaced during maintenance work are available as spare parts These parts will be found in the corresponding spare parts list Note Regular and conscientious maintenance increases the service life of Daily maintenance 1 Clean the injector see therefore the user manual of the OptiFlow injector 2 Clean the powder gun For more on this please also review the user manual for th
7. rot on the A5 display T10 T11 The help codes are stored in an error list in the order of their appearance Each error in the list must be individually acknowledged with the keys T10 or T11 The errors are displayed in the order of their appearance The T10 and 111 keys cannot be used for other functions as long as an error code is still shown Here is a list of all possible error functions for the OptiFlex 2 CG09 manual gun control unit Pneumatics Valve defective hardware contact Gema Service Purge valve i defective Valve defective main board or contact Gema Service Trigger valve cable defective Supplementary air flow The preset value for Lower supplementary air value too high supplementary air is too high or increase value for conveying Setting of supplementary compared to the conveying air air to equalize air volumes to the air on the display setting injector delete error code OptiFlex 2 W e 43 V 03 13 The preset value for conveying Lower conveying air value or Conveying air volume too air is too high compared to the increase value for high setting of powder supplementary air setting supplementary air to equalize air share on the display volumes to the injector delete error code The powder output multiplied by Reduce powder output the powder hose length factor Powder output higher and daily correction value is than 100 greater than 100 Daily correction value too large Reduce daily correction
8. the gun control unit with the ON key The displays illuminate and the control unit is ready for operation 2 Place powder hopper on the mobile trolley WARNING When setting the powder hopper onto the mobile trolley of the manual equipment the hopper trolley zone represents a threat of crushed toes Wear safety shoes with steel toecaps 3 Set the ventilation Airmover a Open the ball valve completely b Calibrate with the throttle valve 4 Fill in powder a Open the powder hoper filling cover b Fill with maximum 25 kg 50 1 powder or the powder must reach to a maximum of 5 10 cm below the handles of the powder hopper otherwise the fluidized powder can escape from the cover e 19 Gema W i c Close the filling cover of the powder hopper again Set coating parameters Press the application button for the appropriate preset mode flat parts complicated parts ES overcoat o The arrow above the desired button lights up OR 7 Press lt p gt program key c Select desired program 01 20 d Change coating parameters as required O Note 1 Programs 01 20 are preset at the factory but can be modified at any time after which they are automatically stored 0 1 Nm h for OptiFlex B and S 8 Setting the total air volume 20 e OptiFlex 2 W Wi Gema correct powder cloud too little total air Note 1 A total air volume of 4 Nm h and a 50 powder share are recommended as the base values
9. value The theoretical value for Limit conveying air to their conveying air falls below minimum value Conveying air range minimum lower deviation Total air is smaller than minimum High voltage Hi Bun error contact Gema Service H4 Grounded current measurement contact Gema Service Power supply Power pack defective or contact Gema Service overloaded Power pack defective or contact Gema Service overloaded EEPROM equipment memory H24 H27 e I EEPROM error contact Gema Service Throttle motors H60 H71 fa TT O Throttle motor error contact Gema Service Help codes list The last appeared four errors are stored in a list by the software If an error appears which is already in the list he will not be listed again Appearance of errors It is possible that an error is only displayed for a short time but after the acknowledgement it will disappear In this case it s recommended to switch off the control unit and switch it on again reset by restarting 44 e OptiFlex 2 W Wi Gema Spare parts list Ordering spare parts When ordering spare parts for powder coating equipment please indicate the following specifications Type and serial number of your powder coating equipment Order number quantity and description ofeach spare part Example Type OptiFlex 2 W Serial number 1234 5678 Order no 203 386 1 piece Clamp 18 15 mm When ordering cable or hose material the requi
10. 1 For further information see the corresponding operating manual which can be found on the accompanying CD Structure OptiFlex 2 W manual coating equipment Structure 1 OptiFlex 2 CGO9 control unit 10 2 OptiFlex 2 GM03 manual powder gun 11 3 OptiFlow injector 12 4 Wall bracket 13 5 Suction tube 14 OptiFlex 2 W Filter unit Gun holder Hose holder PowerClean module Shelf Gema Bi Scope of delivery OptiFlex 2 CGO9 control unit in a metal case with power supply cable Wall bracket with gun hose holder filter unit Suction tube plug in OptiFlow injector OptiFlex 2 CM03 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 CMO3 manual powder gun Pneumatic hoses for conveying air red supplementary air black fluidizing air black and rinsing air black Operating manual Short instructions 10 o OptiFlex 2 W Wi Gema Technical data OptiFlex 2 W Connectable guns connectable OptiFlex 2 GM03 yes Warning The OptiFlex F manual coating equipment can only be used with the specified gun type Electrical data 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 Connection and output for vibrator on Aux 110 230 VAC output max 100 W 24 VDC max 3W 0 C 40 C 32 F 104
11. 1 equipment parameters P0 as configured in the control unit are correct See operating instructions for the OptiFlex 2 CG09 manual gun control unit Chapter Initial Start up Setting Equipment Type Control unit displays Control unit is not Connect the equipment remain dark although connected to the mains with the mains cable ate unit Is Power pack fuse Replace the fuse enna a defective Power pack defective Contact local Gema representative The gun does not Compressed air not Connect the equipment spray powder present to the compressed air pui SE Seid d Injector throttle motor or Clean the corresponding A an nozzle on injector part the e Is powder hose or powder a gun are clogged Insert sleeve in the Replace injector is clogged Insert sleeve is not Mount insert sleeve installed Fluidization not running Total air incorrectly Set total air correctly configured Default value 4 Nm h Main valve defective Replace main valve Gun LED remains Gun not connected Connect the gun dark although the gun is triggered Gun plug gun cable or Contact local Gema gun cable connection representative defective Remote control on Contact local Gema powder gun defective representative OptiFlex 2 W e 33 Gema 34 e V 03 13 Powder does not adhere to object The objects are Check grounding improperly or reground at better although the gun is insufficiently grounded quality triggered and sprays High voltage and c
12. 1001 673 POE low powder flow 912 18mm 911116 mm 10 15 mm Fast color switches 12 18 mm 1001 674 lu e eine a e High powder flow armo 66 e OptiFlex 2 W OptiFlex 2 W Wi Gema Other accessories 1004 552 1002 069 gt L 6m 1002 161 L 14m 1002 162 800 254 e 67 Gema Wi OptiFlow injector Structure OptiFlow Powder injector type IG06 with coded quick release connections Note The injector is certified for using in the following zone if powder 1 hoses with conductive strips are used and the earthing resistance is less than 1 MOhm 68 e OptiFlex 2 W Wi Gema Powder volume setting for OptiFlow Injector OptiFlex 2 W In order to set the ideal powder volume on the gun control unit it is recommended to select the firmness of the powder cloud or the total air first As guide values for different powder hoses the following can be assumed e Powder hose 74 type 10 mm 3 5 m h e Powder hose 66 type 11 mm 4 5 m h According to the prevailing conditions powder powder hose layout the parts to be coated a low to lowest total air can also be set with the standard hose 74 type Y 10 mm If a very large powder output is required it is recommended to select a larger powder hose internal diameter 12 mm Note It should to be noted that if irregular or pumping conveying occurs as a rule the total air is set too low e 69 Gema Wi Cleaning and maintenance Cleani
13. En Quick reference guide Manual coating equipment OptiFlex 2 W Translation of the original operating instructions Gema Gema V 03 13 Documentation OptiFlex 2 W Copyright 2010 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 OptiFlex OptiTronic OptiGun EasyTronic EasySelect EasyFlow OptiStar OptiSelect OptiFlow and SuperCorona are registered trademarks of Gema Switzerland GmbH OptiMatic OptiMove OptiMaster OptiPlus PowerClean Precise Charge Control PCC MultiTronic and Gematic 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 Swi
14. Remove cover purge with compressed air and clean with a clean dry brush and cloth O Clean the injector and suction intake pipe Please review injector manual for more on this Clean rinsing module Empty remaining powder into a container 6 7 8 Vacuum up container and in particular the bottom 9 Clean container with a cloth 1 0 Reconstruct the powder container Note Do not refill the powder container until just before the next use Never clean the powder container with solvents or water Cleaning the OptiFlex 2 GM03 manual powder gun Frequent cleaning of the gun helps to guarantee the coating quality Note 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 the powder hose from the connection 3 Remove the spray nozzle from the gun and clean it 4 Blow out the gun from the connection in flow direction with compressed air OptiFlex 2 W Di Gema 5 Clean the integrated gun tube with the provided gun brush 6 Blow through the gun with compressed air again 7 Clean the powder hose 8 Reassemble the gun and connect it pa Note 1 Please also review the user manual for the OptiFlex 2 GM03 manual powder gun OptiFlex 2 W e 31 Wi Gema Troubleshooting General information Note o Prior to any troubleshooting measures always check whether the
15. e OptiFlex 2 GM03 manual powder gun 3 Clean the powder hose Please also review the section Color change Weekly maintenance 1 Clean fluidizing suction unit injector rinsing module and powder gun The fluidizing suction unit is placed back into the powder shortly before restarting operation 2 Check the control unit grounding connections to the coating booth the suspension devices of the work pieces or the conveyor chain If in disuse for several days 1 Separate from power mains 2 Clean the coating equipment 3 Turn off the compressed air main supply Powder hose rinsing If longer downtimes take place the powder hose has to be cleaned Procedure 1 Disconnect the powder hose from the hose connection on the injector 2 Point the gun into the booth Blow through the hose manually with a compressed air gun Connect the powder hose again to the hose connection on the injector OptiFlex 2 W e 29 Gema Cleaning 30 e A V 03 13 WARNING If no dust mask or one of an insufficient filter class is worn when cleaning the manual equipment 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 at minimum must be worn during any cleaning work Cleaning the powder container Separate fluidized air cable Remove the injector Remove rinsing module PR
16. e conditions OptiFlex 2 W e 73 Gema B i OptiFlow Powder injector type IG06 OptiFlow IG06 Powder injector complete pos 1 13 1007 780 Conveying air check valve unit red marking complete incl pos 6 8 9 and 12 1005 589 B Supplementary air check valve unit black marking complete incl pos 7 8 9 and 1005 590 13 C Injector body complete incl pos 1 2 10 and 11 1006 530 1 Injector body without pos 2 1006 484 2 O ring Y 16x2 mm 1007 794 3 Insert sleeve PTFE complete 1006 485 4 Hose connection 10 12 mm complete incl pos 4 1 1006 531 4 1 O ring Y 16x1 5 mm 205 141 5 Threaded sleeve 1006 483 6 Connector conveying air NW 5 5 1004 366 7 Connector supplementary air NW 5 5 1004 367 8 O ring 11x1 5 mm 1000 532 9 Filter element D 9 4x27 mm 1003 698 10 Nozzle 1006 488 11 Nozzle fixation complete incl pos 11 1 1007 792 11 1 O ring Y 8x1 mm 1007 793H 12 Body red 1004 369 13 Body black 1004 370 16 Conveying air hose 8 6 mm red 103 500 17 Supplementary air hose Y 8 6 mm black 1008 038 18 Quick release coupling for conveying air hose NW5 8 mm 261 645 19 Quick release coupling for supplementary air hose NW5 d 8 mm 261 637 Powder hose 66 type POE 16 11 mm with conductive strip standard 105 139 Powder hose 74 type POE 15 10 mm with conductive strip 1001 673 Powder hose 75 type POE 18 12 mm with conductive strip 1001 674 Pleas
17. e indicate length Wearing part 74 OptiFlex 2 W Wi Gema OptiFlow Powder injector type IG06 OptiFlow Powder injector type IG06 OptiFlex 2 W e 75
18. ed Error cause Troubleshooting Injector nozzle non return valve Clean the corresponding parts unit powder hose or powder gun and if necessary replace them are clogged Conveying vacuum too low Increase the powder quantity and or total air volume on the control unit Insert sleeve worn not or incorrect Replace or insert it observe the inserted indexing cam Insert sleeve is worn after a short Clean the nozzle if damaged operating duration replace it 72 OptiFlex 2 W Wi Gema Spare parts list Ordering spare parts When ordering spare parts for powder coating equipment please indicate the following specifications Type and serial number of your powder coating equipment Order number quantity and description of each spare part Example Type OptiFlex 2 W Serial number 1234 5678 Order no 203 386 1 piece Clamp 18 15 mm When ordering cable or hose material the required length must also be given The spare part numbers for this kind of bulk stock is always marked with an Wearing parts are always marked with a All dimensions of plastic hoses are specified with the external and internal diameter Example 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d WARNING Only original Gema spare parts should be used because the explosion protection will also be preserved that way The use of spare parts from other manufacturers will invalidate the Gema guarante
19. flat jet nozzle is to be replaced if the spray pattern is no longer a regular oval deeper grooves are in the nozzle slot or even the wall thickness is no longer recognizable the wedge of the electrode holder is worn Nozzles with deflectors if the wedge of the electrode holder is worn down then the electrode holder is to be replaced The OptiFlex 2 GM03 is designed to require only a minimum amount of maintenance 1 Clean gun with dry cloth see chapter Maintenance 2 Check connection points to powder house 3 Replace the powder hoses if necessary OptiFlex 2 W OptiFlex 2 W Wi Gema Replacing parts Except for the replacement of possible defective parts there are very few repairs to be made NOTE The replacement of the cascade and the repair of the powder gun cable connection is only permitted by an authorized Gema Service center Contact your Gema representative for details e 53 Wi Gema Troubleshooting General information Event Causes Corrective action H11 Help code on Gun not connected Connect the gun control unit Gun plug or gun cable Contact local Gema defective representative Remote control on Contact local Gema powder gun defective representative Gun LED remains High voltage adjustment Increase high voltage dark although the gun is set too low HESE Gun plug or gun cable Contact local Gema defective representative LED on gun defective Contact local Gema representative Powder does
20. gger and visually check the powder output 13 Check whether everything is functioning correctly 14 Coating 15 Adjust the coating parameters as necessary 16 Activate the rinsing function periodically Note It prevents the bridging phenomena that can lead to short circuiting when handling powders such as metallic powders In moist or tropical environments any moisture is driven from the injector powder hose and powder gun The LCD segments begin to move on the CGO9 display OptiFlex 2 W Wi Gema Note The PowerClean function can be stopped as required using the P key 1x automatically D wm CE er E em H 2 X manually LL UU The automatic rinsing process is started Injector powder hose gun and spray nozzle are purged using compressed air The automated PowerClean function enables parallel cleaning of other components such as the fluid intake unit powder container etc The operator controls the number and length of the PowerClean impulse by pressing the pistol trigger a second time After completion of the PowerClean procedure the controller switches back to coating mode OptiFlex 2 W e 23 Wi Gema Color change General information When a color change takes place the individual components of the manual coating equipment must be cleaned carefully All powder particles of the former color must be removed during this process The following describes an extreme color change
21. guarantee conditions OptiFlex 2 W e 35 Gema V 03 13 OptiFlex 2 W manual coating equipment Spare Parts 1 CG09 gun control unit complete see corresponding operating manual 1007 018 2 GMO03 manual powder gun complete see corresponding user manual 1008 070 3 IGOG injector complete see corresponding user manual 1007 780 4 Pneumatic connection for conveying air 4 1 Quick release connection NW5 8 mm red 261 645 4 2 Nut with kink protection M12x1 mm 8 mm 201 316 4 3 Plastic tube 8 6 mm red 103 500 5 Pneumatic connection for supplementary air 5 1 Quick release connection NW5 8 mm black 261 637 5 2 Nut with kink protection M12x1 mm Y 8 mm 201 316 5 3 Plastic tube 8 6 mm black with white strip marking 1008 038 6 Rinsing module complete See operating instructions OptiFlex 2 GM03 manual 1007 362 powder gun 7 Pneumatic connection for PowerClean air 7 1 Quick release connection NW5 8 mm 1008 027 7 2 Plastic tube 8 6 mm black 103 152 8 Suction tube complete 339 130 9 Grounding cable complete 301 140 10 Pneumatic group complete see corresponding spare parts list 11 Quick release connection NW7 8 D 13 mm 243 647 12 Locknut PG21 234 869 14 Powder hose 15 10 mm Gm 1001 673 15 Short instructions 1007 143 16 Operating manual 1007 141 Please indicate length 36 e OptiFlex 2 W Wi Gema
22. guide as well as the gun control unit operating manual Note e The remainder of the start up procedure for the OptiFlex 2 GM03 manual powder gun is explicitly described in the operating instructions for the OptiFlex 2 CG09 manual powder gun control unit chapter Initial start up and Daily start up OptiFlex 2 W e 17 Gema W i Setting the device type Note 2 If the control unit is delivered as a integral component of an 1 OptiFlex apparatus then the system parameters will have been factory preconfigured for optimal use For more on this please also see the operating instructions for the OptiFlex 2 CG09 manual gun control unit NOTE 1 The manual gun control unit always starts up to the last configured settings 18 e OptiFlex 2 W Operation Coating A A OptiFlex 2 W Wi Gema DANGER During the coating process the gun can discharge along the body of the coating person 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 WARNING 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 Turn on
23. he regulations in the operating instructions DANGER Danger due to live electricity or moving parts Possible consequences death or serious injury WARNING A N Improper use of the equipment could damage the machine or cause it to malfunction Possible consequences light injuries or damage to the equipment o INFORMATION 1 Useful tips and other information OptiFlex 2 W e 3 Gema AR General information General dangers V 03 13 The OptiFlex 2 W Manual coating equipment is built to the latest specification and conforms to the recognized technical safety regulations It 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 any such non compliant use and the user shall bear sole responsibility for such actions If the OptiFlex 2 W Manual coating equipment 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 f
24. ined for each device type based on the 3 configured air values without AirMover air value for OptiFlex F These values apply for an internal control pressure of 5 5 bar OptiFlex 2 W e 13 Gema i Start up Connection instructions The OptiFlex 2 W 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 Pa a oO Injector PJ Airmover PowerClean module Maintenance unit d Fluidized powder hopper i 1 1 4 H Il Y Connection instructions overview e Note 1 THG compressed AIF MUSI DE NEE OTON ANG MAA 14 e OptiFlex 2 W Wi Gema Connections Compressed air hoses cables Connections Compressed air hoses cables 11 Main alrIN_ Connection compressed air 55 bar 80 PS reet Mains cable connection 100 240 VAC _ 22 Aux Vibration motor connection for OptFiexB as cun Guncablecomesion Fluidizing air connection Electrode rinsing air Ges Conveying air TT Grounding connection aB Supplementary air cofineciion DA Pin assignment Power IN Power IN connection 9 1 Neutral conductor power supply 2 Phase 100 240 VAC PE 3 A Output vibrator or stirrer PE Grounding PE OptiFlex 2 W e 15 Wi Gema Initial start up e Note 1 If a malfunction occurs see the troubleshooting
25. lex 2 W e 61 Gema vos OptiFlex 2 GM03 manual powder gun accessories OptiFlex 2 GMO03 flat spray nozzles overview wearing parts Profiles flat parts NF20 standard nozzle Y 1007 931 1007 934 Complex profiles e NF21 1007 229 and depressions i XxX 1007 932 1007 935 1007 683 NF24 arge surfaces Y 1008 142 1008 147 1008 326 62 OptiFlex 2 W vost Gema OptiFlex 2 GM03 rounded spray nozzles overview wearing parts Field of Suitable for large a n NS04 surfaces R 1008 150 Simm 331341 Lam wa o O24mm 331333 mm 331 333 1008 152 NS04 1008 151 1007 229 Lom D 32 mm 331 325 50mm 345822 50 mm 345 822 OptiFlex 2 W e 63 Gema voit OptiFlex 2 GM03 gun extensions L 150mm L 300 mm NS pa T 1007 718 1007 719 e 1007 746 1007 747 with deflector 24 mm 1007 748 1007 749 64 OptiFlex 2 W vost Gema OptiFlex 2 GM03 spray nozzles for extensions overview wearing parts application Profiles flat part NF25 rofiles flat parts p i g 1007 743 NF26 1007 744 1007 740 NSO9 1008 259 GO 16 mm 331 341 24 mm 331 333 32 mm 331 325 GO 50 mm 345 822 NF25 1007 735 OptiFlex 2 W e 65 1007 684 Complex profiles and depressions y NF26 1007 742 a 1008 258 Suitable for large gt surfaces Ve NSO9 1008 257 Gema voit Powder hoses overview Fast color switches 11 16 mm cy POE Fast color switches 10 15 mm
26. n 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 WARNING The following solvents may not be used to clean the OptiFlex 2 manual powder gun Ethylene chloride acetone ethyl acetate methyl ethyl ketone methylene chloride premium gasoline turpentine tetrachloromethane toluene trichloroethylene xylene e 51 Gema Maintenance 52 e V 03 13 NOTE Only cleaning agents with a flash point of a least 5 Kelvin above the ambient temperature or cleaning places with technical ventilation are allowed Cleaning the spray nozzle Daily or after every shift Clean the inside and outside of the spray nozzle with compressed air Never immerse the parts in solvents Check the seating of the spray nozzles WARNING Make sure that the threaded sleeve is always tightened well If the spray nozzle is just fitted loosely there is danger of a flash over of the gun high voltage which can damage the gun Weekly Remove the spray nozzle and clean on the inside with compressed air If sinterings should have formed then they have to be removed Monthly Check spray nozzle for wear The
27. n handle 11 15 16 17 19 20 Gun cable Powder hose connection Rinsing air connection Trigger Powder hose quick release connection SuperCorona connection OptiFlex 2 W Wi Gema Operating elements LED and remote control buttons Operating elements Designation Function o Display High voltage intensity Powder output key Powder output key Activate stop rinsing process key Scope of delivery OptiFlex 2 GM03 manual powder gun with gun cable 6 m negative polarity Powder hose 6 m ID 10 mm Rinsing air hose 6 m Flat jet nozzle NF20 complete incl electrode holder Flat jet nozzle NF21 Cable tie with Velcro closure Gun cleaning brush Spare parts kit Operating manual Available accessories for more information see spare parts list OptiFlex 2 W e 49 Wi Gema Cleaning and maintenance Clean OptiFlex 2 W ng A NOTE Regular careful cleaning and maintenance extends the service life of the OptiFlex 2 GM03 manual powder gun and ensures long lasting uniform coating quality The parts which are to be replaced during maintenance work are available as spare parts These parts will be found in the corresponding spare parts list Cleaning the manual powder gun NOTE 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 clea
28. ng the injector 1 Remove the injector 2 Remove the powder hose from hose connection 4 Clean the hose connection 4 with compressed air which is free of oil and water and check for wear 4 Clean the injector body 1 with compressed air which is free of oil and water Possible contaminations are visible through the opening of the powder hopper connection 2 5 Reinsert the injector and fix it WARNING If the injector is severely contaminated it must be dismantled Remove the non return valve units 6 and 7 with the correct sized spanner Clean the component parts with compressed air and if necessary dissolve sintered deposits with nitro thinner Do not use acetone do not scrape F ee o Am 1 elt A Gs 1 Injector housing 6 Non return valve unit conveying air 2 Powder hopper connection 7 Non return valve unit supplementary air 4 Powder hose connection 70 e OptiFlex 2 W Wi Gema Cleaning the non return valve units Note Take care when dismantling the non return valve units Blow off the filter elements from the inside to the outside 3 1 Connection plug 2 O ring 3 Filter element Note Do not immerse the filter elements in fluidities or solvents Replacing the insert sleeve OptiFlex 2 W e 71 Gema Di Troubleshooting guide Problem fixing If the powder gun does not spray powder although the control unit is switched on then the injector can be dirty or clogg
29. not High voltage and current Check the high voltage adhere to object deactivated and current setting SC Ss Ge E High voltage cascade Contact local Gema 99 pray defective representative powder The objects are not Check the grounding properly grounded The gun does not Compressed air not Connect the equipment spray powder present to the compressed air although the control Injector or nozzle on the Clean the corresponding pi Is SE and injector powder hose or part SOAN JJS powder gun clogged pressed Insert sleeve in the Clean replace injector is clogged No conveying air Throttle motor Contact local Gema defective representative Solenoid valve defective Front plate defective Contact local Gema representative OptiFlex 2 W e 55 Gema 56 e V 03 13 Event Causes Corrective action Gun achieving only Total air incorrectly Increase the powder poor spray profile configured quantity and or total air volume on the control unit Bend or damage to air Check air lines to lines to injector injector Insert sleeve in the Replace or insert it injector worn or not inserted Fluidization not running see above OptiFlex 2 W Wi Gema Spare parts list Ordering spare parts When ordering spare parts for powder coating equipment please indicate the following specifications Type and serial number of your powder coating equipment Order number quantity and description ofeach spare part Example Type O
30. ound on the accompanying CD or on the homepage www gemapowdercoating com The start up is forbidden until it has been established that the OptiFlex 2 W Manual coating equipment has been set up and wired according to the EU guidelines for machinery Unauthorized modifications to the OptiFlex 2 W Manual coating equipment exempts 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 OptiFlex 2 W Electrical danger A Explosion hazard A Slip hazard OptiFlex 2 W Wi Gema 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 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 Safety precautions specified by local legislation must be observed The plug connec
31. posted in a suitable place 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 Gema Observe the grounding regulations Fire and smoke prohibition V 03 13 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 open
32. ptiFlex 2 W Serial number 1234 5678 Order no 203 386 1 piece Clamp 18 15 mm When ordering cable or hose material the required length must also be given The spare part numbers for this kind of bulk stock is always marked with an Wearing parts are always marked with a All dimensions of plastic hoses are specified with the external and internal diameter Example 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d WARNING Only original Gema spare parts should be used because the explosion protection will also be preserved that way The use of spare parts from other manufacturers will invalidate the Gema guarantee conditions OptiFlex 2 W e 57 Gema Bi OptiFlex 2 GM03 manual powder gun Spare parts list Remarks 1 If apart of the gun body should be broken or the high voltage cascade in the gun body should be defective then the whole gun body has to be sent in for repair 2 Ifthe powder gun cable is defective it is to be completely sent in for repair OptiFlex 2 GM03 manual powder gun complete A negative polarity incl gun cable 6 m rinsing air hose 6 m flat jet nozzle brush 1008 070 and parts kit without powder hose OptiFlex 2 GM03 manual powder gun complete positive polarity incl gun cable 6 m rinsing air hose 6 m flat jet nozzle brush 1008 073 and parts kit without powder hose B Manual po
33. red length must also be given The spare part numbers for this kind of bulk stock is always marked with an Wearing parts are always marked with a All dimensions of plastic hoses are specified with the external and internal diameter Example 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d WARNING Only original Gema spare parts should be used because the explosion protection will also be preserved that way The use of spare parts from other manufacturers will invalidate the Gema guarantee conditions OptiFlex 2 W e 45 Gema Wi OptiFlex 2 CG09 manual gun control unit 1 OptiFlex 2 CGO9 manual gun control unit complete 1007 018 2 Cover 1008 301 OptiFlex 2 CG09 manual gun control unit 46 e OptiFlex 2 W Wi Gema OptiFlex 2 GM03 e Note For further information see the corresponding operating manual which can be found on the accompanying CD Technical data Electrical data Opu 0 C 40 C Temperature range 32 F 104 F Max surface temperature 85 C 185 F Protection type IP64 Approvals C 0102 Ex 12D PTB11 ATEX 5006 Dimensions OptiFlex 2 GM03 Weight 520 g Processible powders OptiFlex 2 GM03 Metallic powder Enamel powder OptiFlex 2 W e 47 Gema Structure 48 e V 03 13 General view O GO N gt Spray nozzle system Threaded sleeve Shaft Cover with remote control and hooks Remote control Gu
34. tions 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 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 m 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
35. tzerland 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 Gema Switzerland GmbH Movenstrasse 17 9015 St Gallen Switzerland Phone 41 71 313 83 00 Fax 41 71 313 83 83 E Mail info gema eu com Homepage www gemapowdercoating com Wi Gema Table of contents General safety regulations 3 OptiFlex 2 W 9 ene clean 11 SAP A RECATA 14 Ruas A ATA 17 Operallo Meas 19 Color Chang nan nn Adi pd ii dis 25 Cleaning and unn re 29 WSROUDIESMOOUING E 33 Spare parts EN 35 OptiFlex 2 CG09 39 JEGEN 43 Spare pais a AAA A 45 OptiFlex 2 GM03 47 Cleaning And maintenance ii 51 Beigl Wgl e e LEE 55 Spare paris EE 57 OptiFlow injector 68 Cleaning Elle Run Te ie Le 70 FOUDIESNOOUNOGUIAS lalla 72 A O ee AA ea 73 OptiFlex 2 W Table of contents e 1 Di Gema General safety regulations This chapter sets out the fundamental safety regulations that must be followed by the user and any third parties using OptiFlex 2 W manual coating equipment These safety regulations must be read and understood in full before the OptiFlex 2 W is put into operation Safety symbols pictograms The following warnings with their meanings can be found in the Gema operating instructions The general safety precautions must also be followed as well as t
36. urrent Press the selection key deactivated application key powder fluidized High voltage cascade Contact local Gema defective representative The powder is not Compressed air not Connect the equipment present to the compressed air Fluidizing air is set too Set the fluidizing air low on the control unit correctly Throttle motor defective Contact local Gema representative No electrode rinsing air Rinsing air throttle motor Contact local Gema defective representative OptiFlex 2 W Wi Gema Spare parts list Ordering spare parts When ordering spare parts for powder coating equipment please indicate the following specifications Type and serial number of your powder coating equipment Order number quantity and description ofeach spare part Example Type OptiFlex 2 W Serial number 1234 5678 Order no 203 386 1 piece Clamp 18 15 mm When ordering cable or hose material the required length must also be given The spare part numbers for this kind of bulk stock is always marked with an Wearing parts are always marked with a All dimensions of plastic hoses are specified with the external and internal diameter Example 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d WARNING Only original Gema spare parts should be used because the explosion protection will also be preserved that way The use of spare parts from other manufacturers will invalidate the Gema
37. wder gun shaft OptiFlex 2 GMO03 incl cascade with Gun cable 2 m negative polarity 1007 971 Gun cable 6 m negative polarity 1007 972 Gun cable 12 m negative polarity 1007 973 Gun cable 2 m positive polarity 1007 974 Gun cable 6 m positive polarity 1007 975 Gun cable 12 m positive polarity 1007 968 1 Threaded sleeve complete 1007 229 2 Flat jet nozzle NF20 complete 1007 931 2 1 Electrode holder complete 1007 683 2 2 Flatjet nozzle NF20 1007 934 Parts set not shown consisting of 1002 359 Cleaning brush Y 12 mm 389 765 Flat jet nozzle NF21 1007 935 Cable clamp 303 070 Hose connector complete for hose interior 11 12 mm 1001 340 Powder hose 10 mm not shown 1001 673 H Powder hose 11 mm not shown 105 139 Wearing part 58 e OptiFlex 2 W Wi Gema OptiFlex 2 GM03 manual powder gun Spare parts list OptiFlex 2 GM03 manual powder gun spare parts list OptiFlex 2 W e 59 Gema V 03 13 PowerClean module 60 e O VP W IN a PowerClean module complete Elastomer valve O ring Y 16x2 mm anti static Fluidizing tube bearing Fluidizing tube Stop pin Wearing part 2 PowerClean module Spare parts 1007 362 1000 089 1007 794 1007 356 1007 355 1007 359 OptiFlex 2 W Wi Gema OptiFlex 2 GM03 manual powder gun SuperCorona 1 SuperCorona PCO5 1008 165 Wearing part SuperCorona spare parts OptiF
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