Powder coating equipment OptiFlex 2 BN (Boron Nitride)
Contents
1. 39 OptiFlex 2 BN Stirrer hopper i 40 OptiFlex 2 BN Stirrer hopper i 41 OptiFlex 2 BN Stirrer drive UNIt satans askan 42 OptiFlex 2 BN Stirrer drive UNIt i 43 OptiFlex 2 BN Pneumatic group ars krakkar 44 2 e Table of contents OptiFlex 2 BN Dn Gema General safety regulations This chapter sets out the fundamental safety regulations that must be fol lowed by the user and third parties using OptiFlex 2 BN manual coating equipment These safety regulations must be read and understood in full before the OptiFlex 2 BN 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 fol lowed as well as the regulations in the operating instructions DANGER Danger due to electrically live or moving parts Possible consequences death or serious injury WARNING A Improper use of the equipment could damage the machine or cause it to malfunction Possible consequences minor injuries or damage to equip ment e INFORMATION 1 Useful tips and other information OptiFlex 2 BN General safety regulations e 3 Gema BA General in formation General dan gers 4 e General safety regulations V 03 13 The OptiFlex 2 BN manual coating equipment is state2. Any operating method which will negatively influence the technical safety of the powder spraying equipment is to be avoided OptiFlex 2 BN Electrical danger A Explosion hazard OptiFlex 2 BN 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 Switzer land 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 opera tion 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 Gema OEM parts are guaranteed to maintain the explosion protection rating If damages occur related t
3. OptiFlex 2 GM03 manual powder gun or OptiGun GA02 automatic gun with gun cable powder hose rinsing air hose and standard nozzle set For more on this see the gun operating manual Communication adaptor only for use with an OptiGun GA02 Automatic powder gun see OptiGun GA02 Auto matic powder gun operating manual Pneumatic hoses for conveying air red supplementary air black fluidizing air black and rinsing air black Operating manual Short instructions Typical properties Characteristics of the functions Processing the powder from the stirrer hopper The OptiFlex 2 BN manual coating equipment allows for powder to be processed out of the stirrer hopper Because of the conical shape of the stirrer recipient the powder can be used completely optimum powder consumption OptiFlex 2 BN Product description e 17 Start up a Gema Preparation for start up Set up OptiFlex 2 BN Basic conditions When starting up the OptiFlex 2 BN manual coating unit the following general conditions impacting the coating results must be taken into con sideration 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 The OptiFlex 2 BN manual coating equipment should always be set up vertically on a flat surface WARNING The manual coating equipment must not under any
4. in flow direction with com pressed air 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 be Note Please also review the corresponding gun user manual OptiFlex 2 BN Cleaning and maintenance e 33 Gema DE Maintenance and cleaning of the filter unit The filter unit on the OptiFlex 2 BN manual coating equipment measures and cleans the compressed air This is where the equipment s main com pressed air connection is located Replacing the filter element Procedure 1 Unscrew the filter glass on the filter unit 2 Remove the complete filter element 3 Replace the filter element 4 Clean the filter glass on the inside and install it again 34 e Cleaning and maintenance OptiFlex 2 BN Gema Troubleshooting General information Note 2 Prior to any troubleshooting measures always check whether the 1 equipment parameters PO as configured in the control unit are cor rect 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 con Connect the equipment remain dark although nected to the mains with the mains cable the control unit is Power pack fuse defec Replace the fuse switched on ti ive Power pack defective Contact local Gema rep resentative The gun does not Comp
5. manual We have en deavored to retain the preferred spelling of the trademarks and regis tered 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 Swit zerland 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 1 313 83 00 Fax 41 71 313 83 83 E Mail info gema eu com Homepage www gemapowdercoating com Dn Gema Table of contents General safety regulations 3 Safety symbols pictogramS iii 3 GONE saa 8 Product specific safety measures i 8 OptiFlex 2 BN Manual coating equipment rr 8 About this manual 9 General MA rn 9 Product description 11 seld ADIGA ss E a a E A sen 11 GUZA UON ecien AR 12 Reasonably foreseeable misuse i 12 EeCNMCa Cate ae a a a aa 12 Connectable GUNNS asamt ita 12 Powder output guide values i 12 AIFIOWTAleS ri anemia 13 FlecltiCaldlasan aags andann AG a AA 13 FPNEUMAUC Cate ER iii 13 DIMENSIONS ie illa 14 Processible powders iii 14 Designandtuncloh Leelee i L
6. to a Gun control unit and externally triggered by short circuiting the two cables of the adaptor piece The adaptor must be switched between the powder gun and the Gun Control unit The two wire cable can be connected to a relay output of a PLC which short circuits both Remote Trigger a Gun ON OFF Potential free switch is not included with the trigger adapter Automatic gun Trigger Adapter for remote triggering Order no 1002 772 Order no 1008 858 Used in combination with CG09 ONLY Not included with the trigger adapter TA a Communication Adapter Remote triggering Connecting guide OptiFlex 2 BN Start up e 23 Gema Initial start up Note 1 If a malfunction occurs see the troubleshooting guide as well as the gun control unit operating manual Note The remainder of the start up procedure for the OptiFlex 2 GM03 manual powder gun is explicitly described in the operating instruc tions for the OptiFlex 2 CG09 manual powder gun control unit chapter Initial start up and Daily start up OptiFlex 2 BN Initial start up e 25 Gema Da Setting the device type Note b If the control unit is delivered as a integral component of an 1 OptiFlex apparatus then the system parameter PO will have been factory preconfigured to the value 2 for optimal use For more on this please also see the operating instructions for the OptiFlex 2 CG09 manual gun control unit NOT
7. E 1 The manual gun control unit always starts up to the last configured settings 26 e Initial start up OptiFlex 2 BN Operation A gt OptiFlex 2 BN Gema Coating WARNING If the manual equipment is not being used for coating in conjunc tion 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 the gun control unit with the ON key The displays illuminate and the control unit is ready for operation 2 Fill the stirrer hopper with powder a Open the hinged flap of the stirrer hopper cover WARNING If the cover to the agitator unit is opened then this can fall shut again during inattentive handling Fingers or hands in the cov er container zone can be crushed NOTE Check whether the discharge flap is closed and not just ajar b Fill in the coating powder in the stirrer recipient Maximum fill ing level of the powder is marked on the inside of the recipi ent useful capacity approx 18 5 dm c Closethe hinged flap of the stirrer recipient cover d The stirrer can be put into operation by pressing manually the button on the cover when filling emptying Set coating parameters 4 Press the application button for the preset mode flat parts pi The a
8. En Operating instructions and spare parts list Powder coating equipment OptiFlex 2 BN Boron Nitride WARNING This equipment was developed for use with electrically non conducting powders The use of electrically con ducting powders like metallic or graphite powders can cause a per manent decrease of functioning Translation of the original operating instructions Gema Gema Dn Documentation OptiFlex 2 BN Copyright 2010 Gema Switzerland GmbH All rights reserved This publication is protected by copyright Unauthorized copying is pro hibited by law No part of this publication may be reproduced photocop ied 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 Op tiStar OptiSelect OptiFlow and SuperCorona are registered trademarks of Gema Switzerland GmbH OptiMatic OptiMove OptiMaster OptiPlus PowerClean Precise Charge Control PCC OptiSpray 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 con cerned approve of or are bound in any form by this
9. able set consisting of 6 Power pack connecting cable 390 550 7 Connecting cable 24 VDC 390 569 8 Grounding wire 391 867 9 Fixture set for power pack board consisting of two pieces each Spacer M3 SW5 5x12 mm 267 775 Spacer M3 SW5 5x10 mm 267 007 Cylinder screw 245 321 Shake proof washer 205 885 10 Fuse 2AT 221 872 11 Adaptor cable for stirrer connection 391 905 12 Gland 265 780 13 Gasket for stirrer motor 393 924 42 e Spare parts list OptiFlex 2 BN Gema V 03 13 OptiFlex 2 BN Stirrer drive unit 11 13 12 2 1 4 3 i de I 3 A A o J Serr aos 4 ve j OptiFlex 2 BN Spare parts list e 43 Gema DE OptiFlex 2 BN Pneumatic group Pneumatic group complete 1008 856 1 Filtercartridge 20 um 1008 239 OptiFlex 2 BN Pneumatic group 44 Sparepartsllt QptiFlex 2 BN Dn Gema OptiFlex 2 BN Spare parts list e 45
10. ainer under the discharge flap Open the discharge flap by pushing the lever towards the column WARNING When opening closing the discharge flap fingers caught between the flap injector bracket and lever can be severely crushed 2 Pressthe Push button on the powder hopper cover and continue to hold it down The powder then empties into the container 3 Remove the injector and the plug covering the second injector hole 4 Clean the injector and the injector connection WARNING Danger of accident Never put fingers or any other objects into the injector seat hole s at the bottom of the powder hopper when the stirrer is operating 5 Remove the cover take care not to damage the stirrer arm 32 e Cleaning and maintenance OptiFlex 2 BN Dn Gema Wipe the hopper cover and stirrer arm with a clean dry brush and a clean cloth Carefully close the cover again taking care of the stirrer arm and fit the injector and hoses The coating equipment is now ready for operation Gun cleaning Frequent cleaning of the gun helps to guarantee the coating quality Note gt Before cleaning the powder gun switch off the control unit The 1 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
11. circumstances be set up near a heat source such as an enameling furnace or an electromagnetic source such as a control cabinet Permissible ambient air temperature must be observed The equipment must be locked in order to prevent the inadvertent rolling Start up e 19 Gema n Mounting instructions The OptiFlex 2 BN manual coating equipment must be set up in accord ance with the setup and connecting instructions included with delivery OptiFlex 2 BN Manual coating equipment 20 e Start up OptiFlex 2 BN ca Gema Connection instructions OptiFlex 2 BN Maintenance unit Injector Kk Connection instructions overview The OptiFlex 2 BN manual coating equipment must be connected in ac cordance with the setup and connection instructions Please also review the operating instructions for the OptiFlex 2 CG09 manual gun control unit Note Use clamp to connect grounding cable to the cabin or the suspen sion arrangement Check ground connections with Ohm meter and ensure 1 MOhm or less Start up e 21 Gema DE me 1 The compressed air must be free of oil and water Note bd The powder hose 12 5 9 5 mm PUR is to be used for hose 1 lengths up to 12 m For lengths beyond that please contact Gema 22 e Start up OptiFlex 2 BN MeN Gema Remote trigger adapter for powder guns Boron Ni tride Adapter An OptiGun GA02 Automatic powder gun can be connected
12. e Lear 15 General VIEW sulle 15 SCODE Ol CCV OY urlare 17 OIG Z BN ina uate E GEIR IR 17 Typical properties Characteristics of the functions rr 17 Processing the powder from the stirrer hopper 17 Start up 19 Preparato n Torsta tip 19 31S Gy CONOINONS allatta 19 OE DR Nn Nn 19 NOURNINGINSITUCUONS ra dr 20 Conneccion ISICON S Ea rs ilaria 21 Remote trigger adapter for powder guns Boron Nitride Adapter 23 Initial start up 25 Setting the device type ii 26 Operan lilla 27 CONO e ti lia 27 Setting the background illumination rss 30 SUO airline 30 Cleaning and maintenance 31 Dallymalntenance a lille 31 OptiFlex 2 BN Table of contents e 1 Gema V 03 13 Weekly maintenance i 31 Biannually maintenance iii 31 If in disuse for several days i 32 Powder hose INSINO abile 32 CIN atei 32 Cleaning the powder container arnar 32 Cume lEaNN G nce 33 Maintenance and cleaning of the filter unit enst rassar 34 Replacing the filter element ii 34 Troubleshooting 35 SEE FATA a aaa 35 Spare parts list 37 Ordering spare parsec ehehe 37 OptiFlex 2 BN manual coating equipment Spare parts 38 OptiFlex 2 BN manual coating equipment Spare parts
13. f the cor responding powder gun 3 Clean the powder hose please also review the section Color change Weekly maintenance 1 Clean the stirrer hopper injector and powder gun 2 Check the control unit grounding connections to the suspension devices of the work pieces Biannually maintenance 1 Check the guide ring A for wear and if necessary replace it otherwise the stirrer hopper can be dammaged gt x gt ae CW OptiFlex 2 BN Cleaning and maintenance e 31 Gema Dn If in disuse for several days 1 Separate from power mains 2 Empty the stirrer hopper 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 in jector Point the gun into the exhaust air unit Blow through the hose manually with a compressed air gun Connect the powder hose again to the hose connection on the in jector Cleaning cleaning the manual equipment then the dust that is stirred up from If no dust mask or one of an insufficient filter class is worn when 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 1 Place an empty cont
14. g equipment is used for any other purposes or substances beyond those indicated here 3 Observance of the operating service and maintenance instruc tions specified by the manufacturer is also part of conformity of use The OptiFlex 2 BN manual coating equipment should only be used maintained and started up by trained personnel in formed 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 BN manual coating equipment has been installed and wired according to the EU Ma chinery Directive 2006 42 EC EN 60204 1 machine safety must also be observed 5 Unauthorized modifications to the OptiFlex 2 BN manual coating equipment exempt the manufacturer from any liability from result ing 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 8 e General safety regulations 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 BN Manual coating equipment The OptiFlex 2 BN is a constituent part of the system and is thus inte grated into the safety sys
15. iFlex 2 BN Manual coating equipment OptiFlex 2 BN Product description e 11 Gema Dn Utilization The OptiFlex BN Electrostatic manual equipment for Boron Nitride with the OptiFlex 2 GM03 Manual powder gun or OptiGun GA02 Automatic powder gun is ideally suited for spraying short bursts of fine grained powder with small powder output volumes Reasonably foreseeable misuse Operation without the proper training The use of electrically conducting powders like metallic or graphite powders Use with insufficient compressed air quality and grounding Use in connection with unauthorized coating devices or com ponents Technical data Connectable guns OptiFlex 2 GM03 yes OptiGun GA02 ves with adaptor Warning The OptiFlex 2 BN manual coating equipment can only be used with the specified gun types Powder output guide values Note 1 In order to ensure a perfect operation the Correction value CO min imum powder output at 0 powder output value must be adjusted For more on this please also see the operating instructions for the OptiFlex 2 CG09 manual gun control unit General conditions for the OptiFlow Injector Powder type Boron Nitride Powder hose mm 12 e Product description OptiFlex 2 BN a Gema 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 ting Fl
16. igger the stirrer runs after for approx 15 20 seconds So open the cover only after the stirrer has stopped By lifting up the stirrer cover the engine switches off 10 Check whether everything is functioning correctly 11 Coating 12 Adjust the coating parameters as necessary OptiFlex 2 BN Initial start up e 29 Gema Dn Setting the background illumination sel 1 Press key The display switches to the following level iTv Gema 5 Za Select the desired brightness Shutdown 1 Release gun trigger 2 Switch off the control unit Note The adjustments for high voltage powder output volume and elec trode rinsing air remain stored If in disuse for several days 1 Separate from power mains 2 Emptythe stirrer hopper clean the coating equipment see the corresponding operating manual 3 Turn off the compressed air main supply 30 e Initial start up OptiFlex 2 BN Non Gema Cleaning and maintenance the OptiFlex 2 BN 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 corre sponding spare parts list Note n n Regular and conscientious maintenance increases the service life of Daily maintenance 1 Cleanthe injector see therefore the user manual of the OptiFlow injector 2 Clean the powder gun see therefore the user manual o
17. ing 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 coat ing 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 OptiFlex 2 BN The stay for persons with cardiac pace makers is forbidden Photographing with flashlight is forbid den Disconnect from mains before maintenance works take place ir Gema As a general rule for all powder spraying installations persons with pacemakers should never enter high voltage areas or areas with elec tromagnetic fields Persons with pacemake
18. joint 12 mm H7 206 369 8 Protective sleeve for cardan joint 206 350 9 Manifold 379 395 10 O ring 67 2 mm 236 403 11 Gasket for discharge flap 303 240 12 Discharge flap with toggle clamp incl pos 11 303 194 13 Blind grommet complete incl pos 14 380 296 14 O ring for blind grommet 231 517 16 Feather key 4x4x12 mm round 269 263 17 Feather key for cardan joint 4x4x16 mm round 206 075 18 Allen grub screw for cardan joint sharp M4x5 mm 214 728 19 Cylinder ribbed Allen screw M6x16 mm 261 823 20 Cylinder ribbed Allen screw M5x12 mm 257 052 21 Stirrer brush 3 7 660 22 Cap screw M4x12 mm 216 798 23 Guide ring 380 318 24 Injector holder 380 288 40 e Spare parts list OptiFlex 2 BN V 03 13 OptiFlex 2 BN Stirrer hopper 20 i Ed IE A an fo VU MU Lo tea Ww A Lei gt ul ni a 24 11 12 p i 23 13 14 19 n a Eg T co 3 OptiFlex 2 BN Spare parts list e 41 Gema cn OptiFlex 2 BN Stirrer drive unit Stirrer drive unit complete pos 1 13 393 940 1 Stirrer motor with gear and stirrer case 393 932 2 Stirrer motor with pinion 268 950 Stirrer motor 269 255 Drive belt 268 941 Electronic board for stirrer control complete incl pos 5 388 173 4 Electronic board for power pack Stirrer Control Power Supply 389 277 5 Mains push button complete with cable 390 542 C
19. o 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 pow der 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 spray ing 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 compa ny must be written in a comprehensible manner in the language of equipment operators and posted in a suitable place General safety regulations e 5 Gema Slip hazard Observe the ground ing regulations Fire and smoke pro hibition 6 e General safety regulations V 03 13 Powder lying on the floor around the powder spraying equipment is a po tentially 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 Ground
20. of the art equip ment 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 re sponsibility for such actions Gema Switzerland GmbH must be consulted before OptiFlex 2 BN 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 regula tions are to be observed Furthermore the country specific safety regulations also must be ob served Additional safety and operation notices can be found on the accompany ing CD or on the homepage www gemapowdercoating com Start up is forbidden until it has been established that the OptiFlex 2 BN manual coating equipment has been set up and wired according to the EU guidelines for machinery Unauthorized modifications to the OptiFlex 2 BN Manual coating equip ment exempt the manufacturer from any liability from resulting damages or accidents The operator must ensure that all users have received appropriate train ing for powder spraying equipment and are aware of the possible sources of danger
21. ow rate fluidizing air OptiFlex S with optional fluid plate 0 1 0 Nm h 0 2 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 The total air consumption for the device is determined based on the 1 3 configured air values These values apply for an internal control pressure of 5 5 bar Electrical data 230 240 VAC 110 120 VAC Connected load Nominal output voltage to the gun Nominal output current to the gun 0 C 40 C 32 F 104 F Max surface temperature 100 C 212 F Pneumatic data Input pressure Dynamic based on pressure i regulator setting Sans Nominal input voltage Temperature range Max oil vapor content of the compressed air 0 1 mg m Max compressed air consumption 7 Nm h ee water vapor content of the compressed 1 3 g m OptiFlex 2 BN Product description e 13 Gema V 03 13 Dimensions Wat Depth Height Weight Processible powders OptiFlex 2 BN Plastic powder Metallic powder Enamel powder 14 e Product description OptiFlex 2 BN Non Gema Design and function General view 15 OptiFlex 2 BN manual coating equipment Structure 1 OptiFlex 2 CGO9 control unit 10 Filter unit 2 OptiFlex 2 GM03 manual powder gun 11 Gun holder 3 OptiFlow injector 12 Hose holder 4 Mobile frame with hand rail 13 Communication adapter 5 Discharge flap 14 Shelf 7 Stirrer hoppe
22. powder gun complete see corresponding user manual 4 Pneumatic connection for conveying air complete incl Pos 4 1 4 2 4 3 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 complete incl Pos 5 1 5 2 and 5 3 5 1 Quick release connection NW5 8 mm black 261 637 5 2 Nut with kink protection M12x1 mm 8 mm 201 316 5 3 Plastic tube 8 6 mm black 1008 038 6 IGO6 injector complete see corresponding user manual 1007 780 7 Stirrer hopper complete see corresponding spare parts list 8 Communication Adapter 1008 858 10 Pneumatic group complete see corresponding spare parts list 11 Quick release connection NW7 8 10 26 mm 239 267 14 Powder hose 12 5 9 5 mm not shown 103 705 15 Short instructions 1007 143 16 Operating manual 1008 262 Please indicate length 38 e Spare parts list OptiFlex 2 BN ca Gema OptiFlex 2 BN manual coating equipment Spare parts 3 15 10 E OptiFlex 2 BN manual coating equipment Spare parts OptiFlex 2 BN Spare parts list e 39 Gema cn OptiFlex 2 BN Stirrer hopper 1 Mini stirrer brush 366 862 2 Main filler cover 1001 730 3 Filler flap 1001 731 4 Hinge 305 472 5 Powder hopper 366 854 6 Gasket for powder container 101 630 7 Cardan
23. r 15 Rubber wheel 8 Filler flap 16 Swivel wheel 17 Automatic gun 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 manu al OptiFlow IG06 injector All information about the OptiFlow injector can be found in the corre sponding enclosed documentation Powder guns and powder hoses All information about the OptiFlex 2 GM03 manual powder gun or OptiGun GA02 automatic gun can be found in the documentation for that equipment enclosed with this manual OptiFlex 2 BN Product description e 15 Gema V 03 13 OptiFlex GM03 gun body DD Flat jet nozzle TT Tp Extensions Powder hose J dai 12 5 9 5 mm for lengths 6 12 m Angled nozzle 90 OptiGun GA02 gun body mi TT Q Hose connection 9 5 mm Order number 367 427 Angled nozzle 60 2 l Angled nozzle 45 Powder guns and powder hoses overview 300 and 500 mm extensions special lengths on request 16 e Product description OptiFlex 2 BN ati Gema Scope of delivery OptiFlex 2 BN OptiFlex 2 CG09 control unit in a metal case with power supply cable mobile trolley with a gun hose support Powder hopper with stirrer and cover inclusive mains adaptor for the stirrer plug in OptiFlow injector
24. ressed air not pre Connect the equipment spray powder alt sent to the compressed air diet Ha pati bas Injector throttle motor or Clean the corresponding ee ee nozzle on injector pow part gun trigger is pressed der hose or powder gun are clogged Insert sleeve in the in Replace jector is clogged Insert sleeve is not in Mount insert sleeve stalled Fluidization not running Total air incorrectly con Set total air correctly figured 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 rep gun cable connection resentative defective Remote control on pow Contact local Gema rep der gun defective resentative OptiFlex 2 BN Troubleshooting e 35 Gema cn Powder does not ad The objects are improp Check grounding re here to object alt erly or insufficiently ground at better quality hough the gun is trig grounded L and sprays High voltage and current Press the selection key DESIRE deactivated application key High voltage cascade Contact local Gema rep defective resentative No electrode rinsing air Rinsing air throttle motor Contact local Gema rep defective resentative Stirrer motor not func Motor condenser broken Contact local Gema rep tioning resentative in Incorrect equipment Configure parameter PO type configured See operating instruc tions for the Op
25. rrow above the desired button lights up OR 5 Press Ga program key a Select desired program 01 20 Initial start up 27 Gema 28 e Initial start up V 03 13 b Change coating parameters as required Note Programs 01 20 are preset at the factory but can be modified at any time after which they are automatically stored 6 Setting the total air volume Note A total air volume of 4 Nm h and a 50 powder share are recom mended as the base values 7 Adjust the powder output volume e g according to the desired coating thickness 3 E Su Gi A Note To achieve maximum efficiency we recommend avoided an overly high powder volume where possible The standard setting of 50 anda total air volume of 4 Nm h is recommended at the start The total air volume is thereby kept constant automatically by the con trol 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 OptiFlex 2 BN MeN Gema 8 Setting the electrode rinsing air sel a Press the key The second display level will be shown Di lt gt p ulu 0 1 0 3 Nm h CK 0 5 1 0 Nm h 9 Pointthe gun into the exhaust air unit not at the object to be coated press the gun trigger and visually check the powder out put Note The stirrer starts by pressing the gun trigger By letting loose the gun tr
26. rs 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 operat ing 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 OptiFlex 2 BN General safety regulations e 7 Gema V 03 13 Conformity of use 1 The OptiFlex 2 BN manual coating equipment is state of the art equipment that conforms to the recognized technical safety regu lations and is designed for normal powder coating applications 2 Anyother 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 Gema Switzerland GmbH must be consulted before OptiFlex 2 BN manual coatin
27. tem of the plant 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 Gema safety regulations OptiFlex 2 BN n Gema About this manual General information This operating manual contains all important information required to work with the OptiFlex 2 BN manual coating equipment It will safely guide you through the start up process and give you references and tips for the op timal 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 refer enced to their enclosed corresponding documents OptiFlex 2 BN About this manual e 9 a Gema Product description Field of application The OptiFlex 2 BN manual coating equipment with stirrer is exclusively intended for electrostatic coating using electrically non conducting pow ders For more on this please also review chapter Technical Data Any other use is considered non compliant The manufacturer is not re sponsible 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 Opt
28. tiFlex 2 CG09 manual gun con trol unit Chapter Initial Start up Setting Equipment Type 36 e Troubleshooting OptiFlex 2 BN Dn Gema Spare parts list Ordering spare parts A OptiFlex 2 BN When ordering spare parts for powder coating equipment please indicate the following specifications Type and serial number of your powder coating equip ment Order number quantity and description of each spare part Example Type OptiFlex 2 BN 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 of this 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 inter nal 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 explo sion protection will also be preserved that way The use of spare parts from other manufacturers will invalidate the Gema guarantee conditions Spare parts list e 37 Gema V 03 13 OptiFlex 2 BN 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 GA02 automatic
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