Manual coating equipment OptiFlex 2 B
Contents
1. OptiFlex 2 B e 27 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 28 OptiFlex 2 B vas Gema Cleaning and maintenance m NOTE Regular and conscientious maintenance increases the service life of the OptiFlex 2 B 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 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 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 Separa2. 32 OptiFlex 2 B W i 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 O 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 e 33 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 GM03 manual powder gun complete see corresponding user manual 1008 070 A IG06 injector complete see corresponding user manual 1007 780 4 Pneumatic connection for conveying air complete incl Pos
3. b Change coating parameters as required O NOTE 1 Programs 01 20 are automatically saved Description Presetting Powder output B 0 Total air O Nm h Electrode rinsing air 0 1 Nm h Fluidizing air 0 1 Nm h for OptiFlex B and S 8 Setting the total air volume 4D GG 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 20 e OptiFlex 2 B n Gema em LI ca much powder little powder NOTE 1 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 A Nm h is recommended at the start The total 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 ge Di GB approx 0 1 Nm h approx 0 5 Nm3 h 11 Setting the fluidization too much electrode rinsing air sel a Press the key The second display level will be shown OptiFlex 2 B e 21 Gema Vosne mi b Ll c Check the powder fluidiza
4. Short circuit in limit switch motor throttle defective contact Gema Service contact Gema Service contact Gema Service Conveying air throttle does Short circuit in limit switch motor contact Gema Service not move throttle defective it switch contact Gema Service OptiFlex 2 B ma Gema Electrode rinsing air throttle Short circuit in limit switch motor contact Gema Service does not move throttle defective a ES Lost steps limit switch defective contact Gema Service E throttle motor defective Supplementary air position Lost steps limit switch defective contact Gema Service lost throttle motor defective Electrode rinsing air Lost steps limit switch defective contact Gema Service position lost throttle motor defective sm i Se Lost steps limit switch defective contact Gema Service Fluidizing air position lost throttle motor defective Communication Mainboard Gun Communication error Mainboard defective contact Gema Service Mainboard PIN Gun not connected connect Communication error Mainboard Gun Gun gun cable or Mainboard Replace or contact Gema defective Service Communication error Mainboard defective contact Gema Service Mainboard 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 afte
5. Spare parts OptiFlex 2 B e 35 Gema Vosne OptiFlex 2 B Pneumatic group Pneumatic group complete 1008 235 1 Filter cartridge 20 um 1008 239 2 Plug 8 mm 238 023 Wearing part en 5T e q d 2 e _ LA di i PAA d EZ gi I i GP Na OptiFlex 2 B Pneumatic group 36 e OptiFlex 2 B n Gema OptiFlex 2 B PowerClean module eer 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 A 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 O 8 6 mm black 103 152 6 Gasket not shown 7 Oring O 16x2 mm NBR70 anti static 2x not shown 8 Cable tie not shown Please indicate length Wearing part OptiFlex 2 B PowerClean module set OptiFlex 2 B e 37 mm Gema OptiStar CG13 NOTE 1 For further information see the corresponding operating manual which can be found on the accompanying CD Structure General view E E EL E EEN Ca ES 1 Front plate with control and 3 Back panel with interfaces di
6. 51 vai Gema Cleaning and maintenance Cleaning OptiFlex 2 B A NOTE Regular careful cleaning and maintenance extends the service life of the OptiSelect 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 clean 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 OptiSelect manual powder gun Ethylene chloride acetone ethyl acetate methyl ethyl ketone methylene chloride premium gasoline turpentine tetrachloromethane toluene trichloroethylene xylene e 53 Gema 54 e V 08 15 NOTE Only cleaning agents with a flash point of a least 5 Kelvin above the ambient temperature or cleaning places with tec
7. NW 5 5 Connector supplementary air NW 5 5 O ring O 11x1 5 mm Filter element O 9 4x27 mm Nozzle Nozzle fixation complete incl pos 11 1 O ring O 8x1 mm Body red Body black Conveying air hose O 8 6 mm red Supplementary air hose O 8 6 mm black Quick release coupling for conveying air hose NW5 0 8 mm Quick release coupling for supplementary air hose NW5 0 8 mm Powder hose 66 type POE O 16 11 mm with conductive strip standard Powder hose 74 type POE Y 15 10 mm with conductive strip Powder hose 75 type POE O 18 12 mm with conductive strip Kink protection Please indicate length Wearing part 1005 590 1006 530 1006 484 1007 794 1006 485 1006 531 205 141 1006 483 1004 366 1004 367 1000 532 1003 698 1006 488 1007 792 1007 793 1004 369 1004 370 103 500 1008 038 261 645 261 637 105 139 1001 673 1001 674 1008 844 OptiFlex 2 B Voss Gema OptiFlow Powder injector type IG06 OptiFlow Powder injector type IG06 OptiFlex 2 B e 77
8. 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 1 313 83 00 Fax 41 71 313 83 83 E Mail info gema eu com mm Gema Table of contents General safety regulations 3 OptiFlex 2 B 9 Eer leit o aptamer te i AA 11 A A A E E 14 IVES ARR AA a 17 O CIN AA PAA AA 19 676 0 e ee Aa aaa a a 25 Cleaning and maintenance 11100 a 29 KAEN getta 31 Spare PANTS NAA AA 33 OptiStar CG13 39 FaultremedViNg rale 43 Spare paris IST 47 OptiSelect GM03 49 Cleaning and maintenance ie 53 UU A Gh olo alli acd naan dee sea aa ba 57 A AA MAA 59 OptiFlow injector 70 Cleaning and maintehnang EE 12 Troubleshooting Ee le EE 14 Spare Dans IS EEN 75 OptiFlex 2 B Table of contents e 1 i Gema General safety regulations This chapter sets out the fundamental safety regulations that must be followed by the user and any third parties
9. part 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 If the powder gun cable is defective it is to be completely sent in for repair OptiSelect GM03 manual powder gun complete A negative polarity incl gun cable 2 m rinsing air hose 6 m flat jet nozzle brush 1008 070 and parts kit without powder hose OptiSelect 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 powder gun shaft OptiSelect GM03 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 Flat jet nozzle NF20 1007 934 Parts set not shown consisting of 1002 359 Cleaning brush 12 mm 389 765 Flat jet nozzle NF21 1007 935 Cable clamp 303 070 Hose connector complete for hose interior O 11 12 mm 1001 340 Powder hose O 10 mm not shown 1001 673 Powder hose O 11 mm not shown 105 139 Wearing
10. sequence has finished O d STOP D I After completion of the rinsing procedure the controller switches back to coating mode 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 o for 3 seconds WARNING The rinsing procedure is started directly Procedure 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 procedure the controller switches back to coating mode e 23 W i 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 RE I ER 27 Dt NG P mA a H E ul Lo DE SH Na h ys d o E po OptiFlex 2 B e 25 Gema Vosne Remove and clean the nozzle purge gun using air 26 e OptiFlex 2 B V 08 15
11. starts up to the last configured settings 18 e OptiFlex 2 B W i Gema Operation Coating DANGER During the coating process the gun can discharge along the body of the coater if not held using its intended handle which has been grounded Always hold gun only by the handle Donot touch any other parts of the gun bg 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 Swivel aside the fluidizing suction unit Place the open powder container on the vibrating table WARNING If a container is placed on the vibrating plate then fingers caught in the gap between the two plates can be crushed 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 KU complicated parts ES overcoat o The arrow above the desired button lights up OptiFlex 2 B e 19 Gema Vosne OR 7 Press Ga program key a Select desired program 01 20
12. 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 Y 10 mm 3 5 m h e Powder hose 66 type O 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 O 10 mm If a very large powder output is required it is recommended to select a larger powder hose internal diameter O 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 71 Gema mm Cleaning and maintenance Cleaning 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 sc
13. 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 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 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 conne
14. 0 mm without nozzle 1007 718 1007 719 with Flat jet nozzle ia 1 E z NF25 1007 746 1007 747 with Round jet nozzle i 9 NS09 1007 748 1007 749 66 e OptiFlex 2 B Vosne Gema OptiSelect GM03 spray nozzles for extensions overview wearing parts application NF25 1007 743 NF26 1007 744 1007 740 NSO9 1008 259 GO 16 mm 331 341 24 mm 331 333 32 mm 331 325 4 50 mm 345 822 OptiFlex 2 B e 6 Profiles flat parts NF25 1007 735 1007 684 Complex profiles and depressions NF26 1007 742 Suitable for large surfaces 1008 258 NSO9 1008 257 Gema Vosne Powder hoses overview Fast color changes 11 16 mm Fast color changes g 10 15 mm 1001 673 low powder flow 12118mm 2 11116 mm 101 15 mm Fast color changes 12 18 mm 1001 674 Typ 75 Typ 66 Typ 74 hiah der fl Material POE Material POE Material POE Ign powder How BB Op tiFlex 2 B OptiFlex 2 B Voss Gema Other accessories 1004 552 1002 069 gt L 6m 1002 161 L 14m 1002 162 800 254 e 69 Gema n OptiFlow injector Structure OptiFlow Powder injector type IG06 with coded quick release connections ps NOTE 1 The injector is certified for using in the following zone if powder hoses with conductive strips are used and the grounding resistance is less than 1 MOhm 70 e OptiFlex 2 B n Gema Powder volume setting for OptiFlow Injector OptiFlex 2 B In order to set
15. 4 1 4 2 4 3 4 1 Quick release connection NW5 O 8 mm red 261 645 4 2 Nut with kink protection M12x1 mm O 8 mm 201 316 4 3 Plastic tube O 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 O 8 mm black 261 637 5 2 Nut with kink protection M12x1 mm O 8 mm 201 316 5 3 Plastic tube O 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 O 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 O 6 mm 200 840 9 2 Nut with kink protection M10x1 mm O 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 0 10 O 26 mm 239 267 12 Rubber damper O 20x25 mm M6 2a 43sh 246 000 13 Hexagon shakeproof nut M6 244 430 14 Powder hose O 15 10 mm 6 m 1001 673 15 Short instructions 1007 143 16 Operating manual 1007 141 Please indicate length 34 OptiFlex 2 B n Gema OptiFlex 2 B manual coating equipment Spare parts list 12 13 OptiFlex 2 B manual coating equipment
16. En Quick reference guide Manual coating equipment OptiFlex 2 B Translation of the original operating instructions Gema Gema V 08 15 Documentation OptiFlex 2 B 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 holders To the best of our
17. Flow 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 OptiFlex 2 B W i Gema Technical data OptiFlex 2 B Connectable guns OptiFlex 2 B connectable OptiSelect GM03 yes WARNING The OptiFlex 2 manual coating equipment can only be used with the specified gun types Electrical data Nominal input voltage Connected load without vibrator Nominal output voltage to the gun eff 10 V Nominal output current to the gun max 1 2 A Connection and output for vibrator on Aux 110 230 VAC output max 100 W 24 VDC max 3 W Connection for rinsing function valve 0 C 40 C 32 F 104 F Max surface temperature 120 C 248 F Temperature range OptiFlex 2 B Tms cu Gema 12 0 V 08 15 Pneumatic data Input pressure Dynamic based on pressure regulator setting 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 Nm3 h Dimensions ommes E Processible powders AY Powder output guide values 5 5 bar 80 psi General conditions for the OptiFlow Injector Powder type Epoxy polyester conveying str rozie Stam ag Powder output Zeroing adjustment Opt
18. cting 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 Electrical All maintenance activities must take place when the powder spraying equipment is switched off danger 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 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 VEG max permissible powder air concentration If the UEG is not known then a value of 10 g m should be considered see EN Explosion hazard 50177 All unauthorized conversions and modifications to the electrostatic spraying eq
19. el 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 OptiFlex 2 B V 08 15 Gema NOTE For further information see the corresponding operating manual which can be found on the accompanying CD Structure OptiFlex 2 B 13 16 OptiFlex 2 B manual coating equipment Structure N CON O dI ka W OptiStar CG13 Gun control unit OptiSelect GM03 manual powder gun OptiFlow injector Mobile frame with hand rail Fluidizing suction unit Vibrating table Powder box Swivel arm with guide sleeve 10 11 12 13 14 15 16 Filter unit Gun holder Hose holder PowerClean module Shelf Rubber wheel Swivel wheel Gema V 08 15 Scope of delivery 10 e 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 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 GM03 manual powder gun OptiStar CG13 Control unit in a metal case with power supply cable plug in Opti
20. ema T1 T2 T9 ee T12 oni pon T16 T17 T13 T14 T15 Input keys and switches Designation Function T1 T8 Input keys for desired values and system parameters T9 Select Switch between display levels Program change T10 T11 Terminating the rinsing mode PowerClean with optional PowerClean module 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 Switchover to system parameter mode Press for at least 5 secs Preset mode for complex parts with depressions fixed values Preset mode for overcoating parts already coated fixed values Switching on the rinsing mode PowerClean with optional PowerClean module T16 T17 Power switch On Off Preset mode for flat parts fixed values 42 OptiFlex 2 B W i Gema Fault remedying Error diagnosis of the software General information The correct function of the OptiStar CG13 Gun control unit is constantly monitored 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 rot on the A5 display l Litt T10 T11 He The help codes are stored in an error list in the order of their appearance Each error in the list must be individuall
21. en 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 n 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 ste
22. es 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 B W i 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 OptiSelect GM03 Serial number 1234 5678 Order no 203 386 1 piece Clamp O 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 0 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 e 59 Gema V 08 15 OptiSelect GM03 manual powder gun Spare parts list Remarks ie If a
23. g equipment Order number quantity and description of each spare part Example Type OptiFlow IG06 Serial number 1234 5678 Order no 203 386 1 piece Clamp O 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 0 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 e 75 Gema V 08 15 OptiFlow Powder injector type IG06 OptiFlow IG06 Powder injector complete pos 1 13 1007 780 1005 589 A Conveying air check valve unit red marking complete incl pos 6 8 9 and 12 OJ a la lo IN la lO CO N O Ol 11 11 1 12 13 16 17 18 19 20 76 e Supplementary air check valve unit black marking complete incl pos 7 8 9 and 13 Injector body complete incl pos 1 2 10 and 11 Injector body without pos 2 O ring Y 16x2 mm Insert sleeve PTFE complete Hose connection Y 10 12 mm complete incl pos 4 1 O ring O 16x1 5 mm Threaded sleeve Connector conveying air
24. he corresponding operating manual which can be found on the accompanying CD Technical data Electrical data open 0 C 40 C Temperature range 32 F 104 F Max surface temperature 85 C 185 F Protection type IP64 Approvals C 0102 x 12D PTB11 ATEX 5006 Dimensions OptiSelect GM03 Weight 520 g Processible powders OptiSelect GM03 Metallic powder Enamel powder OptiFlex 2 B e 49 Gema Structure 50 e V 08 15 General view 1 2 3 6 Spray nozzle system Threaded sleeve Shaft Cover with remote control and hooks Remote control Gun 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 B vos Gema Operating elements LED and remote control buttons Operating elements Designation Function Display High voltage intensity Powder output key Powder output key Modify powder output change programs key Scope of delivery OptiSelect 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 B e
25. hnical 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 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 OptiFlex 2 B Maintenance OptiFlex 2 B n Gema The OptiSelect GMO3 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 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
26. iFlex 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 NM3 h Powder output g min Total air Powder output AN 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 1 3 configured air values depending on the device type These values apply for an internal control pressure of 5 5 bar OptiFlex 2 B e 13 Gema n Commissioning Connection instructions The OptiFlex 2 B manual coating eguipment 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 Fluidizing airhose Injector PowerClean l Ce module 4 Connection instructions overview NOTE 1 The compressed air must be free of oil and water 14 e Maintenance unit 6 10 bar OptiFlex 2 B Vosne Gema Co
27. is only permitted by an authorized Gema Service center Contact your Gema representative for details e 55 W i Gema Fault remedying General information Incidenti 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 Striggerso Gun plug or gun cable Contact local Gema defective representative LED on gun defective Contact local Gema representative Powder does not High voltage and current Check the high voltage adhere to object deactivated and current setting sol bi La 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 ue Is MT and injector powder hose or part a JOM ala 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 B e 57 Gema 58 e V 08 15 Incidenti Caus
28. leeve 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 B e 31 G ema V 08 15 e 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 kA ala and sprays High voltage and current Press the selection key EFSER 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
29. must be free of oil and water Daily 1 Blowoffthe 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 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 NOTE Please also review the user manual for the OptiSelect GM03 manual powder gun OptiFlex 2 B W i Gema Fault remedying General information NOTE e 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 unit Is Power pack fuse Replace the fuse SHO 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 ae St d Injector throttle motor or Clean the corresponding eee ema ce nozzle on injector part the LEE IS powder hose or powder Se gun are clogged Insert sleeve in the Replace injector is clogged Insert s
30. nnections Compressed air hoses cables Connections Compressed air hoses cables 13 Main airIN_ Connection compressed air 55bar 80PS 23 Power IN Mais cable connection 100 240 VAC 2 2 aux Vibration motor connection for OptFiegB s Gun cable connecion _ 12 comeyingaircomecion MEI EI Supplementary air connection CF 14 eter rinsing air connection SE aS Fluidizing air connection H Grounding connection Pin assignment Power IN Power IN connection o 3 1 Neutral conductor power supply 2 Phase 100 240 VAC PE N3 A Output vibrator or stirrer PE Grounding PE OptiFlex 2 B e 15 W i Gema Initial start up NOTE 1 If a malfunction occurs see the troubleshooting guide as well as the gun control unit operating manual NOTE o 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 e 17 Gema Vosne Set head piece 3 maj Setting the device type NOTE 1 If the control unit is delivered as a integral component of an 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
31. part 60 e OptiFlex 2 B n Gema OptiSelect GM03 manual powder gun Spare parts list OptiSelect GM03 manual powder gun spare parts list OptiFlex 2 B e 61 Gema Vosne PowerClean module Option PowerClean module complete 1009 528 1 Elastomer valve 1000 089 2 Oring O 16x2 mm anti static 1007 794 3 Fluidizing tube bearing 1007 356 4 Fluidizing tube 1007 355 5 Retaining bracket 1009 524 6 Gasket 1010 101 7 O ring 27x2 mm 1009 525 Wearing part 7 bga CD 2 PowerClean module Spare parts 62 OptiFlex 2 B n Gema OptiSelect GM03 manual powder gun SuperCorona 1 SuperCorona PCO5 1008 165 Wearing part SuperCorona spare parts OptiFlex 2 B e 63 Gema OptiSelect GM03 manual powder gun accessories OptiSelect GM03 flat jet nozzles overview wearing parts application Profiles flat parts NF20 standard nozzle Y 1007 931 d 1007 934 Complex profiles 5 NF21 1007 229 and depressions Ki 1007 932 1007 935 1007 683 NF24 Large surfaces Ve A 1008 142 isla 1008 326 64 OptiFlex 2 B Vosne Gema OptiSelect GM03 rounded spray nozzles overview wearing parts Field of Threaded sleeve Deflectors application Suitable for large a MG i surfaces GO 16 mm 331 341 GO 24 mm 331 333 1008 152 1007 229 32 mm 331 325 4 50 mm 345 822 NS04 1008 150 OptiFlex 2 B e 65 Gema OptiSelect GMO3 gun extensions L 150 mm L 30
32. r 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 OptiFlex 2 B e 45 W i 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 O 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 e 47 Gema Vosne OptiStar CG13 Gun control unit 1 OptiStar CG13 Gun control unit complete 1009 971 2 Cover 1008 301 CJ ES L LA 3 C3 C3 C3 OptiStar CG13 Gun control unit 48 e OptiFlex 2 B mm Gema OptiSelect GM03 NOTE 1 For further information see t
33. rape u ui A Au ae TS 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 72 o OptiFlex 2 B vos 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 B e 73 Gema n 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 clogged Error cause Fault remedying 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 guantity 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 74 OptiFlex 2 B W i 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 coatin
34. splay elements 2 Enclosure OptiFlex 2 B e 39 Gema Vosne Operating elements Display and input buttons NOTE O e For easier operation of the control unit the preset and actual values 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 Gema 1 a Tala LILI 54 LIP ULI S7 kv ITI LILI s9 Tula LILI remote A KI S15 A5 II LI OptiStar on off Displays Level 1 Designation Function Display of actual values desired values and system parameters Flashes when the possible range is exceeded Display of program numbers error diagnosis codes and status information Powder output display in ei Total air volume display in Nm3 h High voltage display in KV eg Spraying current display in yA Remote operation mode is used as keyboard lock reduced operation is possible eum OU Display of vibration fluidization function Display of predefined operating modes or display of rinsing mode during cleaning 40 OptiFlex 2 B vos Gema Gema S3 S6 19 OptiStar on off Displays and LEDs Level 2 Designation Funetion o o o SB Electrode rinsing air display in Nm h EN Fluidizing display in Nm3 h sia Displayillumination 0 8 OptiFlex 2 B e 41 Gema Vosne Input keys and switches G
35. te 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 e 29 Gema Cleaning A 30 e V 08 15 WARNING If no dust mask 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 Removethe injector 2 Remove rinsing module 3 Remove the fluidizing suction unit 4 Clean the fluidizing suction unit with compressed air Also blow off the suction tube with compressed air DI Clean the injector see therefore the injector user manual Clean rinsing module 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
36. tion 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 bg 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 15 Adjust the coating parameters as necessary 16 Activate the rinsing function periodically e 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 o NOTE 1 The suction unit must be lifted o a Detach the injector b Press these two keys at the same time for 3 seconds c START F g 22 OptiFlex 2 B OptiFlex 2 B n Gema Procedure 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
37. too large Reduce daily correction value The theoretical value for conveying air falls below minimum Limit conveying air to its minimum value Conveying air range lower deviation Total air is smaller than minimum No vibrations in the oscillator cable contact Gema Service break oscillator or gun is defective Intermediate circuit voltage Mainboard defective device is contact Gema Service too high switched off Offset spray current Grounded current measurement contact Gema Service measurement Power supply H Supply undervoltage Power pack defective or overloaded contact Gema Service EEPROM equipment memory contact Gema Service EEPROM content invalid EEPROM error contact Gema Service High voltage Gun error Timeout during EEPROM EEPROM error writing EEPROM error Values not correctly stored contact Gema Service in EEPROM during switching off EEPROM verification erroneous H27 EEPROM error contact Gema Service Throttle motors position not found Supplementary air reference position not found Electrode rinsing air reference position not found does not move Conveying air reference Supplementary air throttle Throttle motor or needle jammed limit switch defective error in motor throttle Throttle motor or needle jammed limit switch defective error in motor throttle Throttle motor or needle jammed limit switch defective error in motor throttle
38. uipment 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 e 5 Gema Slip hazard Observe the grounding regulations Fire and smoke prohibition 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 charges 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 gre
39. using OptiFlex 2 B manual coating equipment These safety regulations must be read and understood in full 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 Gema AR General Information General dangers 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
40. y acknowledged with the keys T10 or T11 The errors are displayed in the order of their appearance The T10 and T11 keys cannot be used for other functions as long as an error code is still shown Here is a list of all possible help codes for the OptiStar CG13 Gun control unit Pneumatics PowerClean valve not connected connect or replace Valve defective PowerClean valve l l l Connection cable defective contact Gema Service Mainboard defective OptiFlex 2 B e 43 Gema V 08 15 Solenoid coil current lower than contact Gema Service l preset limiting value Trigger valve l Valve defective main board or cable defective Supplementary air flow too The preset value for supplementary high air is too high compared to the Setting of supplementary conveying air setting air on the display Lower supplementary air value or increase value for conveying air to egualize air volumes to the injector delete error code H07 The preset value for conveying air is too high compared to the supplementary air setting Lower conveying air value or increase value for supplementary air to equalize air volumes to the injector delete error code Conveying air volume too H08 high setting of powder share on the display The powder output multiplied by the Powder output higher than powder hose length factor and daily 100 correction value is greater than 100 Reduce powder output Daily correction value
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