Gema OptiFlex Pro F Operating Instructions And Spare Parts List
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Gema OptiFlex Pro F Operating Instructions And Spare Parts List

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

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Summary of Contents for Gema OptiFlex Pro F

  • Page 1 Rev. 00 1017 934 Operating instructions and Spare parts list Manual equipment OptiFlex Pro F Spray 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

    Assembly guide ..................... 23 Connection instructions ..................24 Set head piece ...................... 25 Start-up Preparation for start-up ..................27 Basic conditions ..................27 Initial start-up ......................28 Setting the device type ..................28 Table of contents  3 OptiFlex Pro F Spray...
  • Page 4 Materials ....................49 Spare parts list Ordering spare parts ..................... 51 OptiFlex Pro F Spray – Spare parts list ..............52 OptiFlex Pro F Spray – Spare parts ..............53 Powder hopper HF05-50 Spray – Spare parts list ..........54 Powder hopper HF05-50 Spray –...
  • Page 5 Rev. 00 03/19 Diffuser (OptiSelect) ....................56 Pneumatic group ....................57 Table of contents  5 OptiFlex Pro F Spray...

  • Page 7: About These Instructions

    General information This operating manual contains all important information which you require for the working with the OptiFlex Pro F Spray. 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 8: Structure Of Safety Notes

    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." 8  About these instructions OptiFlex Pro F Spray...

  • Page 9: 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 10: 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 11 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 12 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! 12  Safety OptiFlex Pro F Spray...
  • Page 13 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  13 OptiFlex Pro F Spray...
  • Page 14 Rev. 00 03/19 14  Safety OptiFlex Pro F Spray...

  • Page 15: Product Description

    Any other use is considered non-compliant. The manufacturer is not responsible for any incorrect use and the risks associated with such actions are assumed by the user alone! Product description  15 OptiFlex Pro F Spray...

  • Page 16: Versions

    2x 50-300 g/min Application Hot coating Option IIa (Extension Kit) Number of guns Number of pumps Powder output 1x 100-600 g/min 2x 100-600 g/min Reasonably foreseeable misuse – Operation without the proper training 16  Product description OptiFlex Pro F Spray...

  • Page 17: Structure

    (enclosed with this manual)! OptiSpray AP01 Application Pump All information about the OptiSpray AP01 application pump will be found in the corresponding enclosed documentation! Product description  17 OptiFlex Pro F Spray...

  • Page 18: Scope Of Delivery

    The OptiFlex 2 F manual coating equipment processes powder from the fluidized powder container. Freely rotating head piece The manual coating equipment features a rotating and lockable head piece for more ergonomic operation and configuration (in steps of 45°) fig. 3 18  Product description OptiFlex Pro F Spray...

  • Page 19: Technical Data

    The PowderBoost functionality is not available. ATTENTION The gun control unit may only be used with the specified gun types! Electrical data OptiFlex Pro F Spray Nominal input voltage 100-240* VAC Frequency 50-60 Hz Fluctuations of the power supply ±...

  • Page 20: Dimensions

    Rev. 00 03/19 Dimensions OptiFlex Pro F Spray Width 481 mm Depth 822 mm Height 1109 mm Weight ca. 50 kg Processible powders OptiFlex Pro F Spray Plastic powder Metallic powder Enamel powder Powder output (reference values) OptiFlex Pro F Spray Conveying hose till 20 m –...

  • Page 21: Environmental Conditions

    Rev. 00 03/19 Environmental conditions OptiFlex Pro F Spray Utilization in the interior Height up to 2 000 m +5 °C - +40 °C Temperature range (+41 °F - +104 °F) Max. surface temperature +85 °C (+185 °F) 80 % for temperatures to 31 °C,...
  • Page 22 Rev. 00 03/19 22  Product description OptiFlex Pro F Spray...

  • Page 23: Assembly / Connection

    (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 Assembly / Connection  23 OptiFlex Pro F Spray...

  • Page 24: Connection Instructions

    8.1 Application pump no. 2 Gun cable Powder container Pinch valve air hose 10 Compressed air hose Spraying air hose 11 AirMover air hose Transport air hose 12 Fluidizing air hose Control signal cable 24  Assembly / Connection OptiFlex Pro F Spray...

  • Page 25: Set Head Piece

    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 Assembly / Connection  25 OptiFlex Pro F Spray...
  • Page 26 Rev. 00 03/19 26  Assembly / Connection OptiFlex Pro F Spray...

  • Page 27: Start-Up

    – Gun correctly connected – Gun control unit correctly connected – Corresponding power and compressed air supply available – Powder preparation and powder quality OK Start-up  27 OptiFlex Pro F Spray...

  • Page 28: Initial Start-Up

    ATTENTION A wrong parameterization leads to various malfunctions! ► For more on this, please also see the operating instructions for the gun control unit! 28  Start-up OptiFlex Pro F Spray...

  • Page 29: 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 30: Select Predefined Operating Mode (Preset Mode)

    Select the desired program (01-20) Program 20 active Change the 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. 30  Operation OptiFlex Pro F Spray...

  • Page 31: Setting Powder Output And Powder Cloud

    Adjust the total air volume on the gun control unit with the T3/T4 keys – Adjust the total air volume according to the corresponding coating requests correct powder cloud too little total air Operation  31 OptiFlex Pro F Spray...

  • Page 32: 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 (GL). Formula: GL = ZL + TL fig. 8: Air streams in the diffuser adapter Total air Transport air Spraying air 32  Operation OptiFlex Pro F Spray...

  • Page 33: Setting The Electrode Rinsing Air

    (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  33 OptiFlex Pro F Spray...

  • Page 34: Cleaning Mode

    In this cleaning program (key T15), the powder hose on the inlet of the application pump will be cleaned with several air blasts. During this time, the pinch valve on the output to the gun remains closed. 34  Operation OptiFlex Pro F Spray...

  • Page 35: Activating The Cleaning Function

    Select the corresponding cleaning program: START = – The automated cleaning procedure is started. During the parallel operation (system parameter P09=1 Duo) both application pumps are cleaned one after the other. Operation  35 OptiFlex Pro F Spray...

  • Page 36: Pinch Valve 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! 36  Operation OptiFlex Pro F Spray...

  • Page 37: Setting The Background Illumination

    – see AP01 Application pump Operating manual. Setting the background illumination Press the The display switches to the following level: Select the desired brightness Operation  37 OptiFlex Pro F Spray...

  • Page 38: Color Change

    13. Empty remaining powder into a bag 14. Vacuum up the hopper and in particular the bottom 15. Clean container with a cloth 38  Operation OptiFlex Pro F Spray...
  • Page 39 Rev. 00 03/19 16. Reassemble the powder hopper 17. Fill with new powder 20. Prepare the manual coating equipment with new powder for start-up Operation  39 OptiFlex Pro F Spray...
  • Page 40 Rev. 00 03/19 40  Operation OptiFlex Pro F Spray...

  • Page 41: Decommissioning / Storage

    If the physical conditions are maintained, the unit can be stored indefinitely. Space requirements The space requirements correspond to the size of the product. There are no special requirements concerning distance to neighboring equipment. Decommissioning / Storage  41 OptiFlex Pro F Spray...

  • Page 42: Physical Requirements

    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. 42  Decommissioning / Storage OptiFlex Pro F Spray...

  • Page 43: Maintenance / Repairs

    Weekly maintenance Clean the powder hopper, application pump 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  43 OptiFlex Pro F Spray...

  • Page 44: If In Disuse For Several Days

    Replacing the filter element Unscrew the filter glass on the filter unit Remove the complete filter element fig. 9 Replace the filter element Clean the filter glass on the inside and install it again 44  Maintenance / Repairs OptiFlex Pro F Spray...

  • Page 45: 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  45 OptiFlex Pro F Spray...

  • Page 46: Cleaning The Powder Container

    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: Fault Clearance

    Application pump, powder hose Clean the corresponding part gun trigger is pressed or powder gun are clogged Application pump defective Replace Fluidization not running see below Pressure valve in the control Replace unit defective Fault clearance  47 OptiFlex Pro F Spray...
  • Page 48 Fluidizing air is set too low on Adjust the fluidization correctly the control unit Throttle motor defective Contact local Gema representative Airmover pressure incorrectly Adjust Powder flows out of the powder hopper 48  Fault clearance OptiFlex Pro F Spray...

  • Page 49: Disposal

    Requirements on personnel carrying out the work The disposal of the product is to be carried out by the owner or operator. When disposing of components that are not manufactured by Gema, the instructions in the respective manufacturer’s documentation must be observed.
  • Page 50 Rev. 00 03/19 50  Disposal OptiFlex Pro F Spray...

  • Page 51: 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  51 OptiFlex Pro F Spray...

  • Page 52: Optiflex Pro F Spray - Spare Parts List

    Rev. 00 03/19 OptiFlex Pro F Spray – Spare parts list OptiStar CG23-P gun control unit – complete (see corresponding operating manual) OptiSelect Pro GM04 Manual powder gun – complete (see corresponding user manual) Powder hose – dia. 8.1/4.5 mm 1005 454*# Diffuser –...

  • Page 53: Optiflex Pro F Spray - Spare Parts

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

  • Page 54: Powder Hopper Hf05-50 Spray - Spare Parts List

    200 840 Nut with kink protection – M10x1 mm, Ø 6 mm 34.2 201 308 Plastic tube – Ø 6/4 mm, black 34.3 1001 973* * Please indicate length # Wearing part 54  Spare parts list OptiFlex Pro F Spray...

  • Page 55: Powder Hopper Hf05-50 Spray - Spare Parts

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

  • Page 56: Diffuser (Optiselect)

    Screw-in nipple – M7-Ø 6 mm 1008 699 Plastic tube – Ø 6/4 mm 103 144* Plug-in connector – Ø 6-Ø 8 mm 254 894 * Please indicate length # Wearing part fig. 12: Diffuser (OptiSelect) 56  Spare parts list OptiFlex Pro F Spray...

  • Page 57: Pneumatic Group

    Pressure gauge – 0-10 bar, 1/8" 1008 049 Distribution block 1017 816 Screw-in nipple – 1/4", Ø 8 mm 265 136 Plug – Ø 8 mm 238 023 # Wearing part fig. 13: Pneumatic group Spare parts list  57 OptiFlex Pro F Spray...
  • Page 59 Shutdown ............41 Fault clearance ..........47 Sound pressure level ........21 Figure references in the text ......8 Spare parts list ..........51 Start-up ............27 Storage ............41 Intended use ............ 15 Index  59 OptiFlex Pro F Spray...
  • Page 60 Rev. 00...

Table of Contents