Gema OptiFlex Pro F, Operating Instructions And Spare Parts List

Page 1: ...Rev 00 1017 934 EN Operating instructions and Spare parts list Manual equipment OptiFlex Pro F Spray Translation of the original operating instructions ...

Page 2: ...s 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 tr...

Page 3: ...use 16 Structure 17 Overall view 17 Scope of delivery 18 Typical characteristics properties of the functions 18 Processing of the powder from the fluidized powder container 18 Freely rotating head piece 18 Technical Data 19 Connectable guns 19 Electrical data 19 Pneumatic data 19 Dimensions 20 Processible powders 20 Powder output reference values 20 Air flow rates 20 Environmental conditions 21 So...

Page 4: ...torage 41 Storage duration 41 Space requirements 41 Physical requirements 42 Maintenance during storage 42 Maintenance schedule 42 Maintenance works 42 Maintenance Repairs 43 General information 43 Interval 43 Daily maintenance 43 Weekly maintenance 43 If in disuse for several days 44 Gun maintenance 44 Maintenance of the filter unit 44 Cleaning 45 Gun cleaning 45 Cleaning the powder container 46 ...

Page 5: ...Rev 00 03 19 OptiFlex Pro F Spray Table of contents 5 Diffuser OptiSelect 56 Pneumatic group 57 ...

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Page 7: ...g manual describes all options and functions of this manual coating equipment Please note that your manual coating equipment may not be equipped with all described functions Options are marked by double asterisks Keeping the Manual Please keep this Manual ready for later use or if there should be any queries Safety symbols pictograms The following warnings with their meanings can be found in the G...

Page 8: ...for the environment MANDATORY NOTE Information which must be observed NOTICE Useful information tips etc Structure of Safety Notes Every note consists of 4 elements Signal word Nature and source of the danger Possible consequences of the danger Prevention of the danger SIGNAL WORD Nature and source of the hazard Possible consequences of the danger Prevention of the danger Presentation of the conte...

Page 9: ...Safety regulations Work should only be carried out in accordance with the instructions of the relevant documents Always work with the complete original document Basic safety instructions This product is built to the latest specification and conforms to the recognized technical safety regulations and is designed for the normal application of powder coating Any other use is considered non compliant ...

Page 10: ...regulations must be read and understood in all cases prior to start up General information This product is built to the latest specification and conforms to the recognized technical safety regulations and is designed for the normal application of powder coating Any other use is considered non compliant The manufacturer shall not be liable for damage resulting from such use the user bears sole resp...

Page 11: ... 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 product may not be switched on until the booth is in operation If the booth stops the product must switch off too Explosion hazard The control units for the spray guns mus...

Page 12: ... 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 conn...

Page 13: ...r 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 or N95 at minimum must be worn during any cleaning work The operating personnel must wear el...

Page 14: ...Rev 00 03 19 14 Safety OptiFlex Pro F Spray ...

Page 15: ... service and maintenance instructions specified by the manufacturer is also part of conformity of use This product should only be used maintained and started up by trained personnel who are informed about and are familiar with the possible hazards involved Any other use is considered non compliant The manufacturer is not responsible for any incorrect use and the risks associated with such actions ...

Page 16: ...ilds With a powder output of up to 600 g min and an extremely high efficiency best coating results are achieved Application Precise powder transport Option I Ia Extension Kit Number of guns 1 1 1 Number of pumps 1 1 1 Powder output 1x 50 300 g min 2x 50 300 g min Application Hot coating Option II IIa Extension Kit Number of guns 1 1 1 Number of pumps 2 2 2 Powder output 1x 100 600 g min 2x 100 600...

Page 17: ... 9 AirMover 10 Shelf 11 OptiStar CG23 P Gun control unit 12 Gun holder OptiSelect Pro GM04 manual powder gun All information about the OptiSelect Pro GM04 manual powder gun can be found in the documentation for that equipment enclosed with this manual OptiStar 4 0 Gun control unit All information about the OptiStar 4 0 Type CG23 P manual gun control unit can found in the documentation for that equ...

Page 18: ...Pump mobile trolley with a gun hose support Fluidized powder hopper Pneumatic hoses for transport air blue spraying air black pinch valve air green and fluidizing air black Operating manual Short description Typical characteristics properties of the functions Processing of the powder from the fluidized powder container The OptiFlex 2 F manual coating equipment processes powder from the fluidized p...

Page 19: ...0 240 VAC Frequency 50 60 Hz Fluctuations of the power supply 10 Overvoltage category OVC II Connected load 140 VA Nominal output voltage to the gun 12 V Nominal output current to the gun 1 2 A Connection and output for vibrator on Aux output 100 240 VAC max 100 W Connection for rinsing function valve 24 VDC max 3 W Protection type IP54 Approvals II 3 D preset country specific voltage Pneumatic da...

Page 20: ... total air volume is maintained constant OptiFlex Pro F Spray Range Factory setting Flow rate fluidizing air Device type B 0 1 0 Nm h 0 1 Nm h Device type F without AirMover air requirements 0 5 0 Nm h 1 0 Nm h Electrode rinsing air flow rate 0 5 0 Nm h 0 1 Nm h Flow rate total air at 5 5 bar 5 Nm h Transport air flow rate 0 5 5 Nm h Spraying air flow rate 0 5 5 Nm h The max total air consumption ...

Page 21: ...ee of pollution of the intended environment 2 in accordance with DIN EN 61010 1 Sound pressure level OptiFlex Pro F Spray Normal operation 60 dB A The sound pressure level was measured while the unit was in operation measurements were taken at the most frequent operator positions and at a height of 1 7 m from the ground The specified value is applicable only for this product itself and does not ta...

Page 22: ...Rev 00 03 19 22 Product description OptiFlex Pro F Spray ...

Page 23: ...rrounding temperature too high Install the equipment only in locations with an ambient temperature of between 5 and 40 C i e never next to heat sources such as an enameling furnace or electromagnetic sources such as a control cabinet Assembly guide The manual coating equipment must be set up in accordance with the setup and connecting instructions included with delivery fig 5 ...

Page 24: ...nufacturer Just a few cables and hoses must be connected fig 6 Connecting guide overview 1 Electrode rinsing air hose 2 Powder hose 3 Gun cable 4 Pinch valve air hose 5 Spraying air hose 6 Transport air hose 7 Control signal cable 8 Application pump no 1 8 1 Application pump no 2 9 Powder container 10 Compressed air hose 11 AirMover air hose 12 Fluidizing air hose ...

Page 25: ... grounding cable to the booth or the suspension arrangement Check ground connections with Ohm meter and ensure 1 MOhm or less The compressed air must be free of oil and water Close the unused connections with the provided dust protection caps Set head piece 1 2 3 4 ...

Page 26: ...Rev 00 03 19 26 Assembly Connection OptiFlex Pro F Spray ...

Page 27: ...ons When starting up the gun control unit the following general conditions impacting the coating results must be taken into consideration Gun correctly connected Gun control unit correctly connected Corresponding power and compressed air supply available Powder preparation and powder quality OK ...

Page 28: ...ed in the operating instructions for the OptiStar CGxx manual powder gun control unit chapter Initial start up and Daily start up Setting the device type If the control unit is supplied as a component of a manual coating unit then the corresponding system parameter is set correctly by the factory ATTENTION A wrong parameterization leads to various malfunctions For more on this please also see the ...

Page 29: ...ating 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 Place powder hopper on the mobile trolley CAUTION Foot injury When setting the powder hopper onto the mobile trolley of the manual equipment the hopper trolley zone represents a threat of cr...

Page 30: ...odes have preset values for high voltage and spray current Application mode Preset µA Preset kV flat parts 100 100 complicated parts 22 100 overcoat 10 100 3 The air values for total air powder output and electrode rinsing air can be individually defined and are saved in the programs Starting the individual adjustable programs 1 Turn on the gun control unit with the ON key 2 Press the program key ...

Page 31: ... be operated with powder at least 1 2 hour after starting up After the running in of the filter elements a stable powder output value will be reached As a factory default value a powder rate of 60 and a total air volume of 4 Nm h are recommended If values are entered that the gun control unit cannot implement then the operator is informed of this by a blinking in the relevant display and a tempora...

Page 32: ...y the control unit To achieve maximum efficiency we recommend avoided an overly high powder volume where possible 2 Check fluidization of the powder in the powder container 3 Point the gun into the booth switch the gun on and visually check the powder output Setting the spraying air The spraying air ZL will be set in accordance to the calculated transport air TL and the adjusted total air volume G...

Page 33: ...second display level will be shown 2 Adjust the correct electrode rinsing air according to the applied nozzles deflector plate flat jet nozzle 0 1 Nm h 0 5 Nm h too much electrode rinsing air 3 If in this display level is no operation for 3 seconds the first display level is switched over independently ...

Page 34: ...ith a pressure of max 4 bar Cleaning the hose to the gun CAUTION Large dust formation possible The conveying hose and the powder gun must be pointed into the booth during the cleaning procedure In this cleaning program key T14 the powder hose to the gun will be cleaned with several air blasts During this time the pinch valve on the suction side remains closed Cleaning the hose on the suction side ...

Page 35: ...problems Manual coating equipment type B Lift the fluidizing suction unit Point the fluidizing suction unit and the gun into a suction unit or into the booth Manual coating equipment type F Remove the hose feedthrough from the powder hopper Point the hose feedthrough and the gun into a suction unit or into the booth 1 OR 2 Select the corresponding cleaning program OR OR 3 START The automated clean...

Page 36: ...alve diagnostic The pinch valve diagnostic is to be carried out in order to maintain the coating quality or after the error message H89 is displayed The prerequisites for the diagnostic Exhaust at suction and conveyance side must be present and in operation Powder hopper must be empty Cleaning program completed The pinch valve diagnostic is to start after the cleaning program has been completed 1 ...

Page 37: ...If the error message H87 H187 suction pinch valve or H88 H188 conveying pinch valve is displayed after the procedure has been completed the corresponding pinch valve hoses must be replaced see AP01 Application pump Operating manual Setting the background illumination 1 Press the key The display switches to the following level 2 Select the desired brightness ...

Page 38: ...ion tube holder 3 4 5 Point the gun into a suction unit or into the booth 6 Keep the hose feedthrough off the body and point it into a suction unit or into the booth 7 Activate the cleaning mode either on the rear of the powder gun remote control or on the control unit 8 Select the corresponding cleaning program See chapter Activating the cleaning function on page 35 9 Press the gun trigger The au...

Page 39: ...Rev 00 03 19 OptiFlex Pro F Spray Operation 39 16 Reassemble the powder hopper 17 Fill with new powder 18 19 20 Prepare the manual coating equipment with new powder for start up ...

Page 40: ...Rev 00 03 19 40 Operation OptiFlex Pro F Spray ...

Page 41: ...powder hose see therefore the corresponding user manuals 3 Turn off the compressed air main supply Storage conditions Hazard notes There is no danger to personnel or the environment if the unit is stored properly Type of storage For safety reasons the product should only be stored in a vertical position Storage duration If the physical conditions are maintained the unit can be stored indefinitely ...

Page 42: ...ements Storage must be inside a dry building at a temperature between 5 and 50 C Do not expose to direct sunlight Maintenance during storage Maintenance schedule No maintenance schedule is necessary Maintenance works During long term storage periodically perform a visual check ...

Page 43: ...stent high coating quality The parts to be replaced during maintenance work are available as spare parts These parts can be found in the appropriate spare parts list Interval Daily maintenance 1 Clean the application pump see therefore the application pump user manual 2 Clean the powder gun For more on this please also review the user manual for the manual gun 3 Clean the powder hose Please also r...

Page 44: ...e again to the hose connection on the application pump Gun maintenance The gun is designed to require only a minimum amount of maintenance 1 Clean the gun with dry cloth see chapter Maintenance 2 Check connection points to powder house 3 Replace the powder hoses if necessary Maintenance of the filter unit The filter unit on the manual coating equipment measures and cleans the compressed air This i...

Page 45: ... turpentine tetrachloromethane toluene trichloroethylene xylene Only cleaning agents with a flash point of a least 5 Kelvin above the ambient temperature or cleaning places with technical ventilation are allowed 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 Wee...

Page 46: ...ottom 6 Clean the hopper with a cloth 7 Reassemble the powder hopper Do not refill the powder container until just before the next use Repair work In the event of malfunctions or faults the product must be checked and repaired by an authorized Gema service workshop The repairs must only be performed by an authorized specialist Improper tampering can result in serious danger for user and equipment ...

Page 47: ...Power pack defective Contact local Gema representative Gun LED remains dark although the gun is triggered High voltage adjustment is set too low Increase high voltage Gun plug or gun cable defective Contact local Gema representative LED on gun defective Contact local Gema representative Powder does not adhere to object although the gun is triggered and sprays powder High voltage and current deacti...

Page 48: ...volume on the control unit Bend or damage to air lines to application pump Check air lines to application pump Pinch valve hose in the application pump worn Replace Fluidization not running see below No electrode rinsing air Rinsing air throttle motor defective Contact local Gema representative The powder is not fluidized Compressed air not present Connect the equipment to the compressed air Fluid...

Page 49: ... by Gema the instructions in the respective manufacturer s documentation must be observed Disposal regulations The product must be disassembled and disposed of properly at the end of its service life When disposing of the product the applicable local and regional laws directives and environmental regulations must be complied with Materials The materials must be sorted according to material groups ...

Page 50: ...Rev 00 03 19 50 Disposal OptiFlex Pro F Spray ...

Page 51: ...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 internal diameter Example Ø 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d ATTENTION Use of non original Gema spare parts When usi...

Page 52: ...neumatic connection for conveying air complete incl Pos 9 1 9 2 and 9 3 1008 035 9 1 Quick release connection NW5 Ø 6 mm 200 840 9 2 Nut with kink protection M10x1 mm Ø 6 mm 201 308 9 3 Plastic tube Ø 6 4 mm black 1001 973 10 Rubber buffer Ø 35x40 mm M8 211 664 12 Rubber wheel Ø 200 mm 260 592 13 Hose clamp Ø 15 18 mm 203 386 14 Quick release connection NW7 8 Ø 10 mm 239 267 15 Pneumatic group com...

Page 53: ...Rev 00 03 19 OptiFlex Pro F Spray Spare parts list 53 OptiFlex Pro F Spray Spare parts fig 10 ...

Page 54: ...002 127 23 Suction tube complete L 504 mm incl pos 24 31 1017 970 24 Suction restrictor complete incl pos 24 1 1015 094 24 1 O ring Ø 8x2 mm NBR70 242 470 25 Powder hose dia 8 1 4 5 mm 1005 454 26 Locknut 234 869 27 Suction tube holder complete incl pos 28 1017 969 28 O ring Ø 28 3x1 78 mm NBR70 224 987 29 Hose connection complete incl pos 29 1 1017 967 29 1 O ring Ø 11x1 5 mm 1000 532 30 Hose fee...

Page 55: ...Rev 00 03 19 OptiFlex Pro F Spray Spare parts list 55 Powder hopper HF05 50 Spray Spare parts fig 11 Powder hopper HF05 50 Spray ...

Page 56: ...1 Adaptor piece 1011 636 2 O ring Ø 12x1 5 mm 1000 822 3 O ring Ø 13x1 5 mm 1009 943 4 Fluidizing tube 1005 262 5 Connector 1011 634 6 Screw in nipple M7 Ø 6 mm 1008 699 7 Plastic tube Ø 6 4 mm 103 144 8 Plug in connector Ø 6 Ø 8 mm 254 894 Please indicate length Wearing part fig 12 Diffuser OptiSelect ...

Page 57: ...in valve 1008 238 3 Connector NW7 4 1 4 256 730 4 Elbow joint 1 4 1 4 222 674 5 Sealing plug 1 8 203 297 6 R F unit 0 8 bar 1 4 complete incl pos 1 and 2 1008 236 7 Double nipple 1 4 1 4 divisible 261 165 8 Pressure gauge 0 10 bar 1 8 1008 049 9 Distribution block 1017 816 10 Screw in nipple 1 4 Ø 8 mm 265 136 11 Plug Ø 8 mm 238 023 Wearing part fig 13 Pneumatic group ...

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Page 59: ...cal data 19 Environmental conditions 21 F Fault clearance 47 Figure references in the text 8 I Intended use 15 M Maintenance 43 Maintenance during storage 42 O Operation 29 P Periodic checks 46 Pictograms 7 Pneumatic data 19 Powder output reference values 20 Presentation of the contents 8 Product description 15 Product specific security regulations 10 R Rating plate 21 Repair work 46 Repairs 43 S ...

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