Gema OptiFlex 2 F Quick Reference Manual
  1. Manuals
  2. Brands
  3. Gema Manuals
  4. Paint Sprayer
  5. OptiFlex 2 F
  6. Quick reference manual

Gema OptiFlex 2 F Quick Reference Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

EN
Rev. 00
1007 142
Quick reference guide
Manual equipment
OptiFlex 2 F
Translation of the original operating instructions

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the OptiFlex 2 F and is the answer not in the manual?

Questions and answers

randy kincaid
June 18, 2025

fluidization wont go above 1.0 it will go below but not above like its locked in at that setting. how can i change or fix this?

0

Subscribe to Our Youtube Channel

Related Manuals for Gema OptiFlex 2 F

Summary of Contents for Gema OptiFlex 2 F

  • Page 1 Rev. 00 1007 142 Quick reference guide Manual equipment OptiFlex 2 F Translation of the original operating instructions...
  • Page 2 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.

  • Page 3: Table Of Contents

    Presentation of the contents ................... 6 Safety General information ....................7 Basic safety instructions ..................7 Product specific security regulations ..............8 OptiFlex 2 F Structure ........................ 13 Scope of delivery ....................14 Technical Data ...................... 14 Assembly / Connection Connection instructions ..................
  • Page 4 Fault clearance Faults ........................61 Spare parts list Ordering spare parts ..................... 63 OptiFlex 2 F – Spare parts list ................64 OptiFlex 2 F – Spare parts ................... 65 Pneumatic group ....................66 PowerClean module set** ..................67 OptiStar CG13 Gun control unit................68 Front plate and power pack ..................

  • Page 5: About These Instructions

    General information This operating manual contains all important information which you require for the working with the OptiFlex 2 F. It will safely guide you through the start-up process and give you references and tips for the optimal use when working with your powder coating system.

  • Page 6: Presentation Of The Contents

    Figure references in the text Figure references are used as cross references in the descriptive text. Example: "The high voltage (H) created in the gun cascade is guided through the center electrode." 6  About these instructions OptiFlex 2 F...

  • Page 7: Safety

    If this product is to be used for other purposes or other substances outside of our guidelines then Gema Switzerland GmbH should be consulted.

  • Page 8: Product Specific Security Regulations

    If this product is to be used for other purposes or other substances outside of our guidelines then Gema Switzerland GmbH should be consulted.
  • Page 9 The use of other parts can lead to risk of injury. Only original Gema spare parts should be used! Repairs must only be carried out by specialists or by authorized Gema service centers. Unauthorized conversions and modifications can lead to injuries and damage to the equipment and invalidate the Gema Switzerland GmbH guarantee.
  • Page 10 As a general rule for all powder spraying installations, persons with The stay for persons pacemakers should never enter high voltage areas or areas with with cardiac pacemakers electromagnetic fields. Persons with pacemakers should not enter areas is forbidden with powder spraying installations! 10  Safety OptiFlex 2 F...
  • Page 11 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. Safety  11 OptiFlex 2 F...
  • Page 12 Rev. 00 09/16 12  Safety OptiFlex 2 F...

  • Page 13: Optiflex 2 F

    OptiStar CG13 Gun control unit 11 Gun holder OptiSelect GM03 manual gun 12 Hose holder OptiFlow injector 13 PowerClean module** Frame 14 Shelf Fluidized powder hopper 15 Rubber wheel AirMover 16 Swivel wheel 10 Filter unit OptiFlex 2 F  13 OptiFlex 2 F...

  • Page 14: Scope Of Delivery

    – Operating manual – Short description Technical Data Connectable guns ATTENTION The OptiFlex 2 F Manual coating equipment may only be used with the specified gun types! OptiFlex 2 F connectable OptiSelect GM03 Electrical data OptiFlex 2 F Nominal input voltage...
  • Page 15 General conditions for the OptiFlow Injector Powder type Epoxy/polyester Length of powder hose (m) Powder hose Ø (mm) Type of powder hose POE with guide strips Input pressure (bar) Powder output zeroing Correction value C0 adjustment OptiFlex 2 F  15 OptiFlex 2 F...
  • Page 16 The total air consumption for the device is determined based on the 3 configured air values (without AirMover air value). – These values apply for an internal control pressure of 5.5 bar! 16  OptiFlex 2 F OptiFlex 2 F...

  • Page 17: Assembly / Connection

    Rev. 00 09/16 Assembly / Connection Connection instructions fig. 2: Connecting guide – overview PowerClean™ module Electrode rinsing air hose (Option) OptiSelect GM03 manual 10 Compressed air hose Assembly / Connection  17 OptiFlex 2 F...
  • Page 18 3: Connections Connection Description Compressed air connection 1.1 Main air IN 2.1 Power IN Mains cable connection 2.2 Aux Vibration motor connection for OptiFlex 2 B 2.3 Gun Gun cable connection 18  Assembly / Connection OptiFlex 2 F...

  • Page 19: Set Head Piece

    Rev. 00 09/16 Connection Description 2.4 Power Clean Connection to rinsing module Conveying air connection Supplementary air connection Electrode rinsing air connection Fluid air connection Grounding connection Set head piece Assembly / Connection  19 OptiFlex 2 F...
  • Page 20 Rev. 00 09/16 20  Assembly / Connection OptiFlex 2 F...

  • Page 21: Start-Up

    Fig. 4 The remainder of the start-up procedure for the Gun is explicitly described in the operating instructions for the OptiStar CG08/CG13 powder gun control unit (chapter "Initial start-up" and "Start-up")! Start-up  21 OptiFlex 2 F...

  • Page 22: Setting The Device Type

    ATTENTION A wrong parameterization leads to various malfunctions! ► For more on this, please also see the operating instructions for the OptiStar CG13 gun control unit! 22  Start-up OptiFlex 2 F...

  • Page 23: Operation

    ► The manual equipment may only be operated in conjunction with a sufficiently powerful suction unit (such as Gema Classic Open booth). Place powder hopper on the mobile trolley...
  • Page 24 Select desired program (01-20) Program 20 active Change coating parameters as required Programs 01-20 are preset at the factory but can be modified at any time, after which they are automatically stored. 24  Operation OptiFlex 2 F...
  • Page 25 (deflector plate, flat jet nozzle) ≈ 0,1 Nm³/h ≈ 0,5 Nm³/h too much electrode rinsing air If in this display level is no operation for 3 seconds, the first display level is switched over independently. Operation  25 OptiFlex 2 F...
  • Page 26 Point the gun into the booth (not at the object to be coated), press the gun trigger and visually check the powder output Check whether everything is functioning correctly Coating Adjust the coating parameters as necessary Activate the rinsing function periodically 26  Operation OptiFlex 2 F...

  • Page 27: Rinsing Mode

    The rinsing mode can only be activated from standby mode (main menu display, no powder conveying). On OptiFlex 2 F Manual coating equipment, the injector must be disconnected prior to cleaning procedure, on OptiFlex 2 B, the suction unit must be lifted, and on OptiFlex 2 S, the powder container must be empty.
  • Page 28 Manual equipment with optional PowerClean module (system parameter P01= 1 or P01=2) The rinsing mode can only be activated from standby mode (main menu display, no powder conveying). START = 28  Operation OptiFlex 2 F...
  • Page 29 The operator controls the number and length of the Manual PowerClean impulse by pressing the gun trigger a (manual) second time STOP = the cleaning mode is terminated automatically. After completion of the PowerClean procedure, the controller switches back to coating mode. Operation  29 OptiFlex 2 F...

  • Page 30: Color Change

    All powder particles of the former color must be removed during this process! The following describes an 'extreme' color change (light to dark). 10. Remove and clean the nozzle, purge gun using air 30  Operation OptiFlex 2 F...
  • Page 31 17. Clean the suction tube 18. Empty remaining powder into a container 19. Vacuum up the hopper and in particular the bottom 20. Clean container with a cloth 21. Reassemble the powder hopper 22. Fill with new powder Operation  31 OptiFlex 2 F...
  • Page 32 Rev. 00 09/16 32  Operation OptiFlex 2 F...

  • Page 33: Decommissioning / Storage

    If in disuse for several days Separate from power mains Clean guns, injectors and powder hoses (see therefore the corresponding user manuals) Turn off the compressed air main supply Decommissioning / Storage  33 OptiFlex 2 F...
  • Page 34 Rev. 00 09/16 34  Decommissioning / Storage OptiFlex 2 F...

  • Page 35: Maintenance / Repairs

    Weekly maintenance Clean powder container, injector, rinsing module** and powder gun. Check the control unit grounding connections to the coating booth, the suspension devices of the work pieces, or the conveyor chain Maintenance / Repairs  35 OptiFlex 2 F...
  • Page 36 The gun is designed to require only a minimum amount of maintenance. Clean the gun with dry cloth, see chapter "Maintenance" Check connection points to powder house. Replace the powder hoses, if necessary. 36  Maintenance / Repairs OptiFlex 2 F...

  • Page 37: Cleaning

    Clean the integrated gun tube with the brush supplied if necessary Blow through the gun with compressed air again Clean the powder hose Reassemble the gun and connect it Maintenance / Repairs  37 OptiFlex 2 F...
  • Page 38 Empty remaining powder into a container Vacuum up the hopper and in particular the bottom Clean container with a cloth 10. Reassemble the powder hopper Do not refill the powder container until just before the next use! 38  Maintenance / Repairs OptiFlex 2 F...

  • Page 39: Fault Clearance

    Injector or nozzle on the Clean the corresponding part gun trigger is pressed injector, powder hose or powder gun clogged Insert sleeve in the injector is Clean/replace clogged Fluidization not running see below Fault clearance  39 OptiFlex 2 F...
  • Page 40 Fluidizing air is set too low on Set the fluidizing air correctly the control unit Throttle motor defective Contact local Gema representative Airmover pressure incorrectly Adjust Powder flows out of the powder hopper 40  Fault clearance OptiFlex 2 F...

  • Page 41: Optistar Cg13

    For further information, see the corresponding operating manual, which can be found on the accompanying CD. Design and function Overall view fig. 5: Front plate with control and Back panel with interfaces display elements Enclosure OptiStar CG13  41 OptiFlex 2 F...
  • Page 42 Spraying current (display in µA) Remote operation mode is used as keyboard S12 remote lock, reduced operation is possible Activation of vibration/fluidization Display of predefined operating modes or display of rinsing mode during cleaning 42  OptiStar CG13 OptiFlex 2 F...
  • Page 43 8: Input keys and switches Designation Function Input keys for desired values and system T1-T8 parameters T9 (Select) Switch between display levels – Program change – T10-T11 Terminating the rinsing mode (PowerClean) with optional PowerClean module OptiStar CG13  43 OptiFlex 2 F...
  • Page 44 (fixed values) – Preset mode for overcoating parts already coated (fixed values) – Switching on the rinsing mode (PowerClean) with optional PowerClean module (Press for at least 5 secs.) T16/T17 Power switch On/Off 44  OptiStar CG13 OptiFlex 2 F...

  • Page 45: Fault Clearance

    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 this Gun control unit: Fault clearance  45 OptiFlex 2 F...
  • Page 46 Description Criteria Remedy Pneumatics: – PowerClean valve not connect or replace connected – Valve defective Contact a Gema service PowerClean valve – Connection cable center defective – Mainboard defective Solenoid coil current lower than Contact a Gema service preset limiting value...
  • Page 47 Rev. 00 09/16 Code Description Criteria Remedy EEPROM verification Contact a Gema service EEPROM error erroneous center Throttle motors: Throttle motor or needle Contact a Gema service Conveying air reference jammed, limit switch defective, center position not found error in motor throttle...
  • Page 48 Rev. 00 09/16 48  Fault clearance OptiFlex 2 F...

  • Page 49: Optiselect Gm03

    Gun cable Threaded sleeve Powder hose connection Shaft 10 Powder hose quick release connection Cover with remote control and hooks 11 Electrode rinsing air connection Remote control 12 Trigger SuperCorona connection Gun handle OptiSelect GM03  49 OptiFlex 2 F...

  • Page 50: Scope Of Delivery

    SuperCorona ring  Flat jet nozzle (for specific applications)  Round jet nozzles  Gun extension 150 and 300 mm  Gun cable extensions  Application cup 150 and 500 ml  Multi-spray adapter 50  OptiSelect GM03 OptiFlex 2 F...

  • Page 51: Technical Data

    Max. surface temperature 85 °C (+185 °F) Protection type IP64 Approvals 0102 II 2D PTB 11 ATEX 5006 Dimensions OptiSelect GM03 Weight 520 g Processible powders OptiSelect GM03 Plastic powder Metallic powder Enamel powder OptiSelect GM03  51 OptiFlex 2 F...
  • Page 52 Rev. 00 09/16 52  OptiSelect GM03 OptiFlex 2 F...

  • Page 53: Fault Clearance

    Replace unit defective Solenoid valve in the control Replace unit defective No conveying air: – Throttle motor defective Contact local Gema – representative Solenoid valve defective Front plate defective Contact local Gema representative Fault clearance  53 OptiFlex 2 F...
  • Page 54 Bend or damage to air lines to Check air lines to injector injector Insert sleeve in the injector Replace or insert it worn or not inserted Fluidization not running see above 54  Fault clearance OptiFlex 2 F...

  • Page 55: Optiflow Ig06

    CD. Structure Overall view fig. 11 1. Check valve unit 4. Injector housing (supplementary air) 6. Check valve unit 2. Powder hose quick release (conveying air) connection 3. Powder hopper connection OptiFlow IG06  55 OptiFlex 2 F...

  • Page 56: Powder Volume Setting For Optiflow Injector

    If a very large powder output is required, it is recommended to select a larger powder hose internal diameter (Ø 12 mm). It should to be noted, that if irregular or pumping conveying occurs, as a rule, the total air is set too low! 56  OptiFlow IG06 OptiFlex 2 F...

  • Page 57: Maintenance / Repairs

    ► Remove the check valve units (1 and 6) with the correct sized spanner. ► Clean the component parts with compressed air and, if necessary, dissolve sintered deposits with nitro-thinner. ► Do not use acetone, do not scrape! Reinsert the injector and fix it Maintenance / Repairs  57 OptiFlex 2 F...

  • Page 58: Cleaning The Check Valve Units

    Parts of the check valve unit may be damaged during the dismantling process. ► Blow off the filter elements from the inside to the outside! ► Do not immerse the filter elements in fluidities or solvents fig. 13 Connection/plug Filter element O-ring 58  Maintenance / Repairs OptiFlex 2 F...

  • Page 59: Replacing The Insert Sleeve

    Rev. 00 09/16 Replacing the insert sleeve Maintenance / Repairs  59 OptiFlex 2 F...
  • Page 60 Rev. 00 09/16 60  Maintenance / Repairs OptiFlex 2 F...

  • Page 61: Fault Clearance

    Insert sleeve worn, Replace or install the not or incorrect insert sleeve. inserted Observe the indexing cam! Clean the nozzle, if Insert sleeve is damaged, replace it worn after a short operating duration Fault clearance  61 OptiFlex 2 F...
  • Page 62 Rev. 00 09/16 62  Fault clearance OptiFlex 2 F...

  • Page 63: Spare Parts List

    When using the spare parts from other manufacturers the explosion protection is no longer guaranteed. If any damage is caused by this use all guarantee claims become invalid! ► Only original Gema spare parts should be used! Spare parts list  63 OptiFlex 2 F...

  • Page 64: Optiflex 2 F - Spare Parts List

    Rev. 00 09/16 OptiFlex 2 F – Spare parts list OptiStar CG13 gun control unit – complete (see corresponding operating 1009 971 manual) GM03 manual powder gun – complete (see corresponding user manual) 1008 070 OptiFlow IG06 injector – complete (see corresponding user manual) 1007 780 Pneumatic connection for conveying air –...

  • Page 65: Optiflex 2 F - Spare Parts

    Rev. 00 09/16 OptiFlex 2 F – Spare parts fig. 14 Spare parts list  65 OptiFlex 2 F...

  • Page 66: Pneumatic Group

    Rev. 00 09/16 Pneumatic group Pneumatic group – complete 1008 235 Filter cartridge – 20 µm 1008 239# Plug – Ø 8 mm 238 023 # Wearing part fig. 15: Pneumatic group 66  Spare parts list OptiFlex 2 F...

  • Page 67: Powerclean Module Set

    103 152* Gasket (not shown) O ring – Ø 16x2 mm, NBR70, anti-static (2x) (not shown) Cable tie (not shown) * Please indicate length # Wearing part fig. 16: PowerClean module set** Spare parts list  67 OptiFlex 2 F...

  • Page 68: Optistar Cg13 Gun Control Unit

    OptiStar CG13 Gun control unit – complete 1009 971 Front plate – complete, see corresponding spare parts list Enclosure Backplate – complete, see corresponding spare parts list Cover 1008 301 4 ––––– fig. 17 68  Spare parts list OptiFlex 2 F...

  • Page 69: Front Plate And Power Pack

    Front plate gasket 1007 042 Membrane keypad Spacer sleeve – Ø 3.6/7x5 mm Display 1007 044 Washer – Ø 3.2/7x0.5 mm Locknut – M3 Power pack – 24 VDC 1009 849 fig. 18 Spare parts list  69 OptiFlex 2 F...

  • Page 70: Inside Back Plate

    Motor throttle – complete 1000 064 Plastic tube – Ø 8/6 mm 103 152* Fluidizing pad – 1/8" 237 264 Screw – M4x16 mm 1013 925 * Please indicate length fig. 19: 70  Spare parts list OptiFlex 2 F...

  • Page 71: Connecting Material

    382 485 Mains cable – USA 382 507 Mains cable – GB 382 515 Mains cable – AUS 382 523 Mains cable – China 1000 993 * Please indicate length fig. 20 Spare parts list  71 OptiFlex 2 F...

  • Page 72: Optiselect Gm03 - Spare Parts List

    Hose connection Ø 11-12 mm – complete (incl. pos 15.1) 1001 340 # Hose connection Ø 9-10 mm – complete (incl. pos 15.1) 1002 030 # 15.1 O-ring for pos. 15 1000 822 # Threaded sleeve (see corresponding spare parts list) 72  Spare parts list OptiFlex 2 F...
  • Page 73 Powder hose – Ø 10 mm (not shown) 1001 673*# Powder hose – Ø 11 mm (not shown) 105 139*# * Please indicate length # Wearing part fig. 21: OptiSelect GM03 – spare parts Spare parts list  73 OptiFlex 2 F...

  • Page 74: Powerclean™ Module (Option)

    O ring – Ø 16x2 mm, anti-static 1007 794# Fluidizing tube bearing 1007 356 Fluidizing tube 1007 355 Retaining bracket 1009 524 Gasket 1010 101 O-ring – Ø 27x2 mm 1009 525 # Wearing part fig. 22 74  Spare parts list OptiFlex 2 F...

  • Page 75: Supercorona

    Rev. 00 09/16 SuperCorona SuperCorona PC05 1008 165# # Wearing part Fig. 23 Spare parts list  75 OptiFlex 2 F...

  • Page 76: Accessories

    1007 683 1007 935 Complex parts NF22 (deep recess); 1008 140 target spraying NF22 1008 145 NF24 Large surfaces 1008 142 NF24* 1008 147 1008 326 * not suitable for angled nozzles 76  Spare parts list OptiFlex 2 F...
  • Page 77 Ø 16 mm 331 341 NS04 Suitable for Ø 24 mm large surfaces 1008 150 331 333 NS04 1008 152 Ø 32 mm 1008 151 1007 229 331 325 Ø 50 mm 345 822 Spare parts list  77 OptiFlex 2 F...
  • Page 78 ► The extensions (150 mm/300 mm) may be connected TO ONLY ONE ADDITONAL extension (150 mm/300 mm), if necessary. 78  Spare parts list OptiFlex 2 F...
  • Page 79 Ø 16 mm 331 341 Suitable for NS09 large Ø 24 mm 1008 259 surfaces NS09 331 333 1008 258 1008 257 Ø 32 mm 331 325 Ø 50 mm 345 822 Spare parts list  79 OptiFlex 2 F...
  • Page 80 * Please indicate length Other accessories 150 ml 500 ml Application cup 1004 552 1002 069 Gun extension cables L=6 m 1002 161 L=14 m 1002 162 Gloves, anti-static (1 pair) 800 254 80  Spare parts list OptiFlex 2 F...

  • Page 81: Optiflow Ig06 - Spare Parts List

    Powder hose – 74 type, POE, Ø 15/10 mm, with conductive strip 1001 673*# Powder hose – 75 type, POE, Ø 18/12 mm, with conductive strip 1001 674*# * Please indicate length # Wearing part Spare parts list  81 OptiFlex 2 F...

  • Page 82: Optiflow Ig06 - Spare Parts

    Rev. 00 09/16 OptiFlow IG06 – spare parts fig. 24 82  Spare parts list OptiFlex 2 F...
  • Page 83 Electrical data ..........14, 51 Start-up ............21 Storage ............33 Fault clearance ....... 39, 45, 53, 61 Figure references in the text ......6 Technical Data ........... 14, 51 Maintenance ..........35, 57 Index  83 OptiFlex 2 F...
  • Page 84 Rev. 00...

Table of Contents

Save PDF