Manual coating equipment OptiFlex 2 B
Contents
1. cceeceeeeeeeseeeeeseeeeeeesaeeeeeas 35 Replacing the filter eleMENt ii 35 Fault remedying 37 Ceneralinfiormmatioi ppn le a ala asa 37 Spare parts list 39 OFdering Spare palls snl hehe 39 OptiFlex 2 B manual coating equipment Spare parts list 40 OptiFlex 2 B manual coating equipment Spare parts list 41 OptiFlex 2 B Rneumatic 0i0Up rsissia alla 42 OptiFlex 2 B PowerClean module set 43 2 e Table of contents OptiFlex 2 B Pen Gema General safety regulations This chapter sets out the fundamental safety regulations that must be followed by the user and third parties using OptiFlex 2 B manual coating equipment These safety regulations must be read and understood before the OptiFlex 2 B is put into operation Safety symbols pictograms OptiFlex 2 B 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 the regulations in the operating instructions DANGER Danger due to electrically live 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 light injuries or damage to the equipment INFORMATION Useful tips and other information General safety regulations e 3 Gem2. cas 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 B 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 B Spare parts list e 39 Gema V 08 15 OptiFlex 2 B manual coating equipment Spare parts list 1 CG13 gun control unit complete see corresponding operating manual 1009 971 2 GMO03 manual powder gun complete see corresponding user manual 1008 070 3 IG06 injector complete see corresponding user manual 1007 780 4 Pneumatic connection for conveying air complete incl Pos 4 1 4 2
3. the OptiFlex 2 B manual coating equipment and provides for a longer continuous coating quality gt 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 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 the OptiSelect GM03 manual powder gun 3 Clean the powder hose Please also review the section Color change Weekly maintenance 1 Clean fluidizing suction unit injector PowerClean 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 B Cleaning and maintenance e 33 Gema Vosne Cleaning WARNING If no dust mas
4. 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 PowerClean module complete See operating instructions OptiSelect GM03 1007 362 manual powder gun 7 Pneumatic connection for PowerClean air complete incl Pos 7 1 and 7 2 7 1 Quick release connection NW5 8 mm 1008 027 7 2 Plastic tube 8 6 mm black 103 152 8 Fluidizing suction unit complete 1009 679 9 Pneumatic connection for conveying air complete incl Pos 9 1 9 2 and 9 3 9 1 Quick release connection NW5 6 mm 200 840 9 2 Nut with kink protection M10x1 mm 6 mm 201 308 9 3 Plastic tube 6 4 mm black 1001 973 10 Pneumatic group complete see corresponding spare parts list 11 Quick release connection NW7 8 10 26 mm 239 267 12 Rubber damper 20x25 mm M6 2a 43sh 246 000 13 Hexagon shakeproof nut M6 244 430 14 Powder hose 15 10 mm 6 m 1001 673 15 Short instructions 1007 143 16 Operating manual 1007 141 Please indicate length 40 e Spare parts list OptiFlex 2 B n Gema OptiFlex 2 B manual coating equipment Spare parts list 12 13 OptiFlex 2 B manual
5. data Input pressure Dynamic based on pressure regulator setting 9 9 bar 80 psi A 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 opere E Processible powders 14 Product description OptiFlex2B vas Gema Design and function OptiFlex 2 B General view 13 16 OptiFlex 2 B manual coating equipment Structure 1 OptiStar CG13 Gun control unit 10 Filter unit 2 OptiSelect GM03 manual powder 11 Gun holder gun 3 OptiFlow injector 12 Hose holder 4 Frame 13 PowerClean module 5 Fluidizing suction unit 14 Shelf 6 Vibrating table 15 Rubber wheel 7 Powder box 16 Swivel wheel 8 Swivel arm with guide sleeve OptiSelect GM03 manual powder gun All information about the OptiSelect GM03 manual powder gun can be found in the documentation for that equipment enclosed with this manual OptiStar CG13 Gun control unit All information about the OptiStar CG13 Control unit will be found in the corresponding enclosed documentation OptiFlow injector All information about the OptiFlow injector can be found in the corresponding enclosed documentation Product description e 15 Gema na Scope of delivery OptiFlex 2 B OptiSelect 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 OptiSelect GM
6. 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 B prior to start up General safety regulations e 7 Gema Proper use V 08 15 The OptiFlex 2 B 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 damages resulting fr
7. 03 manual powder gun OptiStar CG13 Control unit in a metal case with power supply cable plug in OptiFlow injector mobile trolley with a gun hose support vibrating base and a fluidizing suction unit PowerClean module 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 directly from the original powder manufacturer s container The OptiFlex 2 B manual coating equipment allows for powder to be processed directly out of the original powder manufacturer s container A titled vibrating floor has been included to ensure that the powder container empties itself completely Freely rotating head piece The OptiFlex 2 B manual coating equipment features a freely rotating and lockable head piece for more ergonomic operation and configuration Freely rotating head piece 16 e Product description OptiFlex 2 B vas Gema Commissioning Preparation for start up Basic conditions When starting up the OptiFlex 2 B 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 Op
8. 1007141 En Operating instructions and spare parts list Manual coating equipment OptiFlex 2 B Translation of the original operating instructions Gema Gema Documentation OptiFlex 2 B V 08 15 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 MagicCompact MagicCylinder MagicPlus MagicControl OptiFlex OptiControl OptiGun OptiSelect OptiStar and SuperCorona are registered trademarks of Gema Switzerland GmbH OptiFlow OptiCenter OptiMove OptiSpeeder OptiFeed OptiSpray OptiSieve OptiAir OptiPlus OptiMaster MultiTronic EquiFlow Precise Charge Control PCC Smart Inline Technology SIT and Digital Valve Control DVC 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
9. WIG AO Ad cioe ie 13 PACUMALIC Galant iti se ahi EN PAL eee he Ci 14 DIMEN SIOS paneer REL LI ai di 14 Processible powders ii 14 DEesignandiuncion salle pino 15 General VIEW cimeira oar e a 15 SCOP SONGS GEY eee 16 COX 2 Braanen a sad de ean sted ioe tesea onde n a 16 Typical properties Characteristics of the functions 16 Processing the powder directly from the original powder manufacturer s OV MAIN aea e aes e eats ed acl S 16 Freely rotating head piece 16 Commissioning 17 PreparationTorstarelipiiineaiiea ia 17 BASIC condilion 52 hola iaia 17 SCerupr siutl eee hee eo Pe Taam hei 17 VIOLET CUINS UEEICE ONS hoi stan a a a aa 18 Connection INSHFUCHONS liacle 19 Initial start up 21 SU INS AG DIECO Lacan 22 Setting the device VPe irrita 22 OS AOA pie aci 23 Callao 23 Setting the background illumination 28 Colorchandeice lieta 29 Generalinfonmationi reina 29 SUINA ticolare 32 Table of contents e 1 Gema V 08 15 Cleaning and maintenance 33 Daily MEINE NANG Girato 33 Weekly maintenance viccsivnaeosts lia 33 If in disuse for Several daySs iii 33 POWdEer nosetrisingisileiiali ili 33 Ciegnintrbie calette 34 Cleaning the fluidizing suction UNit 34 Cleaning the OptiSelect GM03 manual powder gun 34 Maintenance and cleaning of the filter UNIt
10. a BA General information General dangers 4 e General safety regulations V 08 15 The OptiFlex 2 B 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 any such non compliant use and the user shall bear sole responsibility for such actions Gema Switzerland GmbH must be consulted before OptiFlex 2 B 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 gemapowdercoating com Start up is forbidden until it has been established that the OptiFlex 2 B manual coating equipment has been set up and wired according to the EU guidelines for machinery Unauthorized modifications to the OptiFlex 2 B Manual coating equipment exempt the manufacturer from any liability from resulting damages or ac
11. ay 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 VEG max permissible powder air concentration If the UEG is not known then a value of 10 g m should be considered see EN 50177 Explosion hazard 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 OptiFlex 2 B General safety regulations e 5 Gema Slip hazard Observe the grounding regulations Fire and smoke prohibition 6 e General safety regulations V 08 15 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 c
12. cidents 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 B n 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 the Gema Switzerland GmbH guarantee would no longer be valid 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 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 Electrical equipment is switched off danger 9 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 t00 The control units for the spray guns must be installed and used in zone 22 Spr
13. coating equipment Spare parts OptiFlex2B Spare parts list e 41 Gema Vosne OptiFlex 2 B Pneumatic group Pneumatic group complete 1008 235 1 Filter cartridge 20 um 1008 239 2 Plug 8mm 238 023 Wearing part per n a gt a va fi T P ee ee OptiFlex 2 B Pneumatic group 42 e Spare parts list OptiFlex 2 B n Gema OptiFlex 2 B PowerClean module set PowerClean module set rinsing air hose length 2 m pos 1 2 3 4 8 1010 519 PowerClean module set rinsing air hose length 12 m pos 1 2 3 1 8 1010 520 1 PowerClean module complete See operating instructions OptiSelect GM03 1009 528 manual powder gun 2 Solenoid valve complete 1009 928 3 PowerClean module cable complete length 1 m 1009 879 3 1 PowerClean module cable complete length 15 m 1009 880 4 Quick release connection NW5 8 mm 1008 027 5 Plastic tube 8 6 mm black 103 152 6 Gasket not shown 7 Oring 16x2 mm NBR7O anti static 2x not shown 8 Cable tie not shown Please indicate length Wearing part OptiFlex 2 B PowerClean module set OptiFlex 2 B Spare parts list e 43 Gema na 44 Spare parts list OptiFlex2B
14. harges can have the following consequences Charges to people electric shocks sparking Proper grounding must be in place to prevent objects from becoming charged Earthing 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 flames are forbidden in the entire plant area No work that could potentially produce sparks is allowed OptiFlex 2 B The stay for persons with cardiac pacemakers is forbidden Photographing with flashlight is forbidden Disconnect from mains before maintenance works take place vas Gema As a general rule for all
15. holders To the best of our knowledge and belief the information contained in this publication was correct and valid on the date of publication Gema Switzerland GmbH makes no representations or warranties with respect to the contents or use of this publication and reserves the right to revise this publication and make changes to its content without prior notice For the latest information about Gema products visit www gemapowdercoating com For patent information see www gemapowdercoating com patents or www gemapowdercoating us patents Printed in Switzerland Gema Switzerland GmbH Movenstrasse 17 9015 St Gallen Switzerland Phone 41 71 313 83 00 Fax 41 71 313 83 83 E Mail info gema eu com sia Gema Table of contents OptiFlex 2 B General safety regulations 3 Safely symbols pictogramSs aicac lalla deeds ted eae 3 ed O12 LUSO elia ie E 8 Product specific Safety MeaSUres nne 8 OptiFlex 2 B manual coating equipment 8 About this manual 9 GerReralinformalon sil lilla ia 9 Product description 11 FieldlroFapplicalioni apsa lo e aan adele Li 11 UUA UOM E 11 Reasonably foreseeable MISUSE 12 TFECNNICaLdala a a a a a libia 12 COMMC Cla DIG GUNS iren a a iii 12 Powder output guide values 12 Guide values for OptiStar CG13 with OptiFlow Injector IG06 13 PUP TOW WANS Soto 3s nes eels lilla 13 EO
16. idization 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 B Fault remedying e 37 G ema V 08 15 Famn causes Faultremedying Powder does not The objects are Check grounding adhere to object improperly or reground at better although the gun is insufficiently grounded quality E and sprays High voltage and current Press the selection key i deactivated application key High voltage cascade Contact local Gema defective representative The powder is not Compressed air not Connect the equipment fluidized 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 Vibrator not functioning Vibrator condenser Contact local Gema broken representative Incorrect equipment Configure parameter type configured P00 See operating instructions for the OptiStar CG13 manual gun control unit Chapter Initial Start up Setting Equipment 38 e Fault remedying OptiFlex 2 B
17. ing table WARNING If a container is placed on the vibrating plate then fingers caught in the gap between the two plates can be crushed gt The container may weight a max of 30 kg 4 Place the fluidizing suction unit onto the powder 5 Set coating parameters 6 Press the application button for the appropriate preset mode flat parts ID complicated parts IR overcoat The arrow above the desired button lights up OR 7 Press Ga program key a Select desired program 01 20 b Change coating parameters as required OptiFlex 2 B Initial start up e 23 Gema Vosne NOTE e Programs 01 20 are preset at the factory but can be modified at any 1 time after which they are automatically stored Description Presetting Powder output High voltage kV 80 kV Electrode rinsing air 0 1 Nm h 8 Setting the total air volume LIT I L correct powder cloud too little total air NOTE A total air volume of 4 Nm h and a 50 powder share are recommended as the base values 9 Adjust the powder output volume e g according to the desired coating thickness ODO amp much powder little powder 24 e Initial start up OptiFlex 2 B OptiFlex 2 B n Gema NOTE To achieve maximum efficiency we recommend avoided an overly high powder volume where possible gt The standard setting of 50 and a total air volume of 4 Nm h is recommended at the start The to
18. k or one of an insufficient filter class is worn when cleaning the Fresh powder system then the dust that is stirred up from the coating powder can cause respiratory problems gt The ventilation system must be turned on for all cleaning work gt A dust mask corresponding to filter class FFP2 at minimum must be worn during any cleaning work Cleaning the fluidizing suction unit 1 Remove the injector Remove the fluidizing suction unit Clean the fluidizing suction unit with compressed air Also blow off the suction tube with compressed air Clean the injector see therefore the injector user manual Reassemble the individual parts Cleaning the OptiSelect 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 Clean the integrated gun tube with the provided gun brush Blow through the gun with compressed air again Clean the powder hose oO amp ol Reassemble the gun and connect it gt NOTE 1 Please also review the user manual for the OptiSelect GM03 manual powder gun 34 e Cleaning and mai
19. l as 1 the gun control unit operating manual NOTE e The remainder of the start up procedure for the OptiSelect GM03 1 manual powder gun is explicitly described in the operating instructions for the OptiStar CG13 manual powder gun control unit chapter Initial start up and Daily start up OptiFlex 2 B Initial start up e 21 Gema na Set head piece yg 1 siii 2 pe 3 i Setting the device type NOTE x 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 OptiStar CG13 manual gun control unit NOTE 1 The manual gun control unit always starts up to the last configured settings 22 e Initial start up OptiFlex 2 B n Gema Operation Coating 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 gt 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 Swivel aside the fluidizing suction unit 3 Place the open powder container on the vibrat
20. n moist or tropical environments any moisture is driven from the injector powder hose and powder gun NOTE 1 The suction unit must be lifted prior to rinsing procedure a Detach the injector b Press these two keys at the same time for 3 seconds The LCD segments begin to move on the display 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 rinsing mode is exited if the automatic rinsing sequence has finished d STOP I After completion of the rinsing procedure the controller switches back to coating mode 26 e Initial start up OptiFlex 2 B n Gema Manual equipment with optional PowerClean module system parameter P01 1 The rinsing mode can only be activated from standby mode main menu display no powder conveying 1 Press the key for 3 seconds WARNING The rinsing procedure is started directly 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 rinsing mode is exited if the automatic rinsing sequence has finished 3 STOP After completion of the PowerClean p
21. ng equipment The OptiFlex 2 B 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 For further security information see the more detailed Gema safety regulations OptiFlex 2 B vai Gema About this manual General information This operating manual contains all important information required to work with the OptiFlex 2 B 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 NOTE This operating manual describes all options and functions of this manual coating equipment gt Please note that your manual coating equipment may not be equipped with all described functions gt Options are marked by double asterisks DANGER Working without operating instructions Working without operating instructions or with individual pages from the operating instructions may result in damage to property and personal injury if relevant safety information is not observed gt Before working with the device organize the required documents and
22. ntenance OptiFlex 2 B n Gema Maintenance and cleaning of the filter unit The filter unit on the OptiFlex 2 B manual coating equipment measures and cleans the compressed air This is where the equipment s main compressed air connection is located Replacing the filter element Procedure 1 Unscrewthe filter glass on the filter unit 2 Remove the complete filter element 3 Replace the filter element 4 Cleanthe filter glass on the inside and install it again OptiFlex 2 B Cleaning and maintenance e 35 vai Gema Fault remedying General information NOTE x Prior to any troubleshooting measures always check whether the 1 equipment parameters P00 as configured in the control unit are correct See operating instructions for the OptiStar CG13 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 1 DRS Power pack fuse Replace the fuse eae 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 PARA to ala d Injector throttle motor or Clean the corresponding e ai nozzle on injector part the DEE is powder hose or powder pune gun are clogged Insert sleeve in the Replace injector is clogged Insert sleeve is not Mount insert sleeve installed Flu
23. om such use the user bears sole responsibility for such actions Gema Switzerland GmbH must be consulted before OptiFlex 2 B 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 OptiFlex 2 B manual coating equipment should only be used maintained and started up by trained personnel informed and familiar with the possible hazards involved Start up i e operation of its intended use is not allowed until it has been established that the OptiFlex 2 B 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 Unauthorized modifications to the OptiFlex 2 B manual coating equipment exempt the manufacturer from any liability from resulting damage The relevant accident prevention regulations as well as other generally recognized safety regulations occupational health and structural regulations are to be observed Furthermore the country specific safety regulations also must be observed Product specific 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 B manual coati
24. read the section Safety regulations gt Work should only be carried out in accordance with the instructions of the relevant documents gt Always work with the complete original document OptiFlex 2 B About this manual e 9 vas Gema Product description Field of application The OptiFlex 2 B with powder box 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 any associated risks 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 B manual coating equipment Utilization The electrostatic OptiFlex 2 B manual coating equipment with the OptiSelect GM03 manual powder gun is ideally suited for manual coating of objects OptiFlex 2 B Product description e 11 Gema Vosne 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 WARNING A N The OptiFlex 2 manual coating equipment can only be used with the specified gun types Powder o
25. rocedure the controller switches back to coating mode OptiFlex 2 B Initial start up e 27 Gema Vosne Setting the background illumination sel 1 Press key The display switches to the following level Gema OptiStar on off Select the desired brightness 28 e Initial start up OptiFlex 2 B Man 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 light to dark Press these two keys at the same time for 3 seconds oo oe Dan n ca E I OptiFlex 2 B Initial start up 29 Gema Vosne Remove and clean the nozzle ic purge gun using air 30 e Initial start up OptiFlex 2 B V 08 15 OptiFlex 2 B Initial start up e 31 Gema Vosne Shutdown 1 Release gun trigger 2 Switch off the control unit NOTE 1 The adjustments for high voltage powder output electrode rinsing air and fluidizing remain stored If in disuse for several days 1 Separate from power mains 2 Clean the coating equipment see the corresponding operating manual 3 Turn off the compressed air main supply 32 e Initial start up OptiFlex 2 B vas Gema Cleaning and maintenance NOTE Regular and conscientious maintenance increases the service life of
26. tal air volume is thereby kept constant automatically by the control unit gt 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 ri l ge Di BB approx 0 1 Nm h 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 fluidization has been incorrectly adjusted then the coating powder can create a dust cloud capable of causing respiratory problems gt Adjust the fluidization correctly 12 Point the gun into the booth not at the object to be coated press the gun trigger and visually check the powder output 13 Check whether everything is functioning correctly 14 Coating Initial start up e 25 Gema Vosne 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 I
27. tiFlex 2 B 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 OptiFlex 2 B Commissioning e 17 Gema P Mounting instructions The OptiFlex 2 B manual coating equipment must be set up in accordance with the setup and connecting instructions included with delivery OptiFlex 2 B manual coating equipment 18 e Commissioning OptiFlex 2 B Man Gema Connection instructions Injector Maintenance unit IDONEO ELETTI a H 6 10 bar il s B Fluidizing p i J air hose F P PowerClean module ly i OptiFlex 2 B Connection instructions overview The OptiFlex 2 B manual coating equipment must be connected in accordance with the setup and connection instructions Please also review the operating instructions for the OptiStar CG13 manual gun control unit 1 2 NOTE Use clamp to connect grounding cable to the cabin or the suspension arrangement Check ground connections with Ohm meter and ensure 1 MOhm or less Commissioning e 19 Gema Vosne z NOTE 1 The compressed air must be free of oil and water 20 e Commissioning OptiFlex 2 B vas Gema Initial start up NOTE gt If a malfunction occurs see the troubleshooting guide as wel
28. utput guide values General conditions for the OptiFlow Injector Powder type Epoxy polyester Power hose POE with ot strips Input thesis bar Correction value CO Powder output zeroing adjustment 12 e Product description OptiFlex 2 B n Gema Guide values for OptiStar CG13 with OptiFlow Injector IG06 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 Nm3 h 5 Nm h Powder output g min Total air Powder output 2 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 Factory Flow rate fluidizing air OptiFlex B 0 1 0 Nm h 0 1 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 3 configured air values These values apply for an internal control pressure of 5 5 bar Electrical data opere Connection and output for vibrator on Aux 110 230 VAC output max 100 W l a 24 VDC Connection for rinsing function valve Temperature range igs 32 F 104 F Max surface temperature 120 C 248 F Approvals C x Il 3 D IP54 120 C OptiFlex 2 B Product description e 13 Gema Pneumatic
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