Gema OptiFlex Pro B Quick Reference Manual
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Gema OptiFlex Pro B Quick Reference Manual

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EN
Rev. 00
1017 556
Quick reference guide
Manual equipment
OptiFlex Pro B
Detailed information and detailed spare parts lists can be found
in the corresponding operating instructions: via the Gema app or
www.gemapowdercoating.com/en/support/operation-manuals.
Translation of the original operating instructions

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Summary of Contents for Gema OptiFlex Pro B

  • Page 1 Rev. 00 1017 556 Quick reference guide Manual equipment OptiFlex Pro B Detailed information and detailed spare parts lists can be found in the corresponding operating instructions: via the Gema app or www.gemapowdercoating.com/en/support/operation-manuals. 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

    Safety General information ....................7 Basic safety instructions ..................7 Product specific security regulations ..............8 OptiFlex Pro B Intended use ......................13 Structure ........................ 14 Scope of delivery ....................15 Typical characteristics – properties of the functions ..........15 Technical Data ......................
  • Page 4 Fault clearance Faults ........................63 Spare parts list Ordering spare parts ..................... 65 OptiFlex Pro B – Spare parts list ................66 OptiFlex Pro B – Spare parts ................67 Fluidizing/suction unit ................... 68 Fluidizing/suction tube – spare parts ..............69 Pneumatic group ....................

  • Page 5: About These Instructions

    General information This operating manual contains all important information which you require for the working with the OptiFlex Pro B. 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 Pro B...

  • 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 Pro B...
  • 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 Pro B...
  • Page 12 Rev. 00 03/19 12  Safety OptiFlex Pro B...

  • Page 13: Optiflex Pro B

    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! OptiFlex Pro B  13 OptiFlex Pro B...

  • Page 14: Structure

    All information about the OptiStar 4.0 (Type CG21) manual gun control unit can found in the documentation for that equipment (enclosed with this manual)! OptiFlow injector All information about the OptiFlow injector will be found in the corresponding enclosed documentation! 14  OptiFlex Pro B OptiFlex Pro B...

  • Page 15: 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 OptiFlex Pro B  15 OptiFlex Pro B...
  • Page 16 In moist or tropical environments, any moisture is driven from the injector, powder hose and powder gun. The color change is also accelerated during non-extreme color switches. fig. 4 16  OptiFlex Pro B OptiFlex Pro B...

  • Page 17: Technical Data

    Compressed air connection 8 mm Max. input pressure 5.5 bar / 80 psi Max. water vapor content of the 1.3 g/m³ compressed air Max. oil vapor content of the 0.1 mg/m³ compressed air OptiFlex Pro B  17 OptiFlex Pro B...
  • Page 18 Hose internal diameter (mm) Ø 11 Hose length (m) Total air volume (Nm³/h) Powder output (g/min) Powder output 135 150 100 185 215 145 235 270 185 280 320 220 18  OptiFlex Pro B OptiFlex Pro B...
  • Page 19 Maximum relative humidity linearly decreasing to 50 % relative humidity at 40 °C Environment not for wet environment Degree of pollution of the 2 (in accordance with DIN EN intended environment 61010-1) OptiFlex Pro B  19 OptiFlex Pro B...
  • Page 20 The specified value is applicable only for this product itself and does not take into account external noise sources or cleaning impulses. The sound pressure level may vary, depending on the product configuration and space constraints. Rating plate fig. 5 20  OptiFlex Pro B OptiFlex Pro B...

  • Page 21: Assembly / Connection

    Electrode rinsing air hose 10 Compressed air hose Powder hose 11 Fluidizing air hose Supplementary air hose 12 Maintenance unit Conveying air hose 13 OptiStar Control unit Control signal cable 14 Rinsing air hose Assembly / Connection  21 OptiFlex Pro B...

  • Page 22: 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 22  Assembly / Connection OptiFlex Pro B...

  • Page 23: Start-Up

    7 The remainder of the start-up procedure for the gun is explicitly described in the operating instructions for the OptiStar CGxx manual powder gun control unit (chapter "Initial start-up" and "Daily start-up")! Start-up  23 OptiFlex Pro B...

  • Page 24: Setting The Device Type

    WARNING: A wrong parameterization leads to various malfunctions! ► For more on this, please also see the operating instructions for the OptiStar CGxx gun control unit! 24  Start-up OptiFlex Pro B...

  • Page 25: Operation

    ► The manual equipment may only be operated in conjunction with a sufficiently powerful suction unit (such as Gema Classic Open booth). Swivel aside the fluidizing/suction unit...
  • Page 26 60 % Total air 4.0 Nm³/h High voltage 80 kV Spray current 20 µA Electrode rinsing air 0.1 Nm³/h Fluidizing air 1.0 Nm³/h (for device type F) 0.1 Nm³/h (for device type B and S) 26  Operation OptiFlex Pro B...
  • Page 27 – Adjust the total air volume according to the corresponding coating requests correct powder cloud too little total air Setting the powder output much powder little powder Adjust the powder output volume (e.g. according to the desired coating thickness) Operation  27 OptiFlex Pro B...
  • Page 28 Configure AirMover by opening the ball valve complete and adjusting with the flow control valve (equipment type F only) Open the powder container cover (equipment type F only) Press the The second display level will be shown 28  Operation OptiFlex Pro B...
  • Page 29 If in this display level is no operation for 3 seconds, the device switches back to the first display level – The powder should only be touched gently, but should be "cooked" regularly and is also to be stirred using a rod Close again the cover Operation  29 OptiFlex Pro B...

  • Page 30: Rinsing Mode

    On manual coating equipment type F, the injector must be disconnected prior to cleaning procedure, on type B, the suction unit must be lifted, and on type S, the powder container must be empty. Detach the injector START = 30  Operation OptiFlex Pro B...
  • Page 31 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 = Operation  31 OptiFlex Pro B...
  • Page 32 Manual PowerClean impulse by pressing the gun trigger a (manual) second time STOP = OR the cleaning mode is terminated automatically. After completion of the PowerClean procedure, the controller switches back to coating mode. 32  Operation OptiFlex Pro B...

  • Page 33: Color Change

    Clean the injector (see therefore the injector user manual) 10. Remove the swivel arm and blow off with a compressed air gun 11. Prepare the manual coating equipment with new powder for start-up Operation  33 OptiFlex Pro B...
  • Page 34 Rev. 00 03/19 34  Operation OptiFlex Pro B...

  • Page 35: 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  35 OptiFlex Pro B...
  • Page 36 Rev. 00 03/19 36  Decommissioning / Storage OptiFlex Pro B...

  • Page 37: Maintenance / Repairs

    Place the fluidizing/suction unit back into the powder shortly before restarting operation Check the control unit grounding connections to the coating booth, the suspension devices of the work pieces, or the conveyor chain Maintenance / Repairs  37 OptiFlex Pro B...
  • Page 38 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. 38  Maintenance / Repairs OptiFlex Pro B...

  • Page 39: 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  39 OptiFlex Pro B...
  • Page 40 Clean the fluidizing/suction unit with compressed air. Also blow off the suction tube with compressed air Clean the injector (see therefore the injector user manual) Clean rinsing module** Reassemble the individual parts 40  Maintenance / Repairs OptiFlex Pro B...

  • Page 41: 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  41 OptiFlex Pro B...
  • Page 42 Contact local Gema Vibrator not functioning representative Vibrator not plugged in plug in Incorrect equipment type Configure parameter P00 (See configured operating instructions for the manual gun control unit, Chapter "Start-up – Setting Equipment Type") 42  Fault clearance OptiFlex Pro B...

  • Page 43: Optistar Cg21

    For further information, see the corresponding operating manual, which can be found on the accompanying CD. Design and function Overall view Fig. 8 Front plate with control and Back panel with interfaces display elements Enclosure OptiStar CG21  43 OptiFlex Pro B...
  • Page 44 Display of predefined operating modes or display of cleaning mode during cleaning – Display of readiness for pairing the Bluetooth module with a mobile device (green) – Display of an active connection (blue) 44  OptiStar CG21 OptiFlex Pro B...
  • Page 45 Electrode rinsing air (display in Nm³/h) Display background illumination (0-8) Input keys and switches fig. 11: Input keys and switches Designation Function Input keys for desired values and system T1-T8 parameters Switch between display levels T10-T11 Program change OptiStar CG21  45 OptiFlex Pro B...
  • Page 46 2 seconds) – Display of the ID number (press for a short time) – Switching on the rinsing mode (PowerClean) with optional PowerClean module – Terminating the rinsing mode (PowerClean) with optional PowerClean module 46  OptiStar CG21 OptiFlex Pro B...

  • Page 47: Fault Clearance

    Here is a list of all possible help codes for this Gun control unit: Code 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 Fault clearance  47 OptiFlex Pro B...
  • Page 48 Rev. 00 03/19 Code Description Criteria Remedy Solenoid coil current lower than Contact a Gema service preset limiting value center Trigger valve Valve defective, main board or cable defective The preset value for Lower supplementary air Supplementary air supplementary air is too high...
  • Page 49 Rev. 00 03/19 Code Description Criteria Remedy Supplementary air Throttle motor or needle Contact a Gema service reference position not jammed, limit switch defective, center found error in motor throttle Electrode rinsing air Throttle motor or needle Contact a Gema service...
  • Page 50 Rev. 00 03/19 50  Fault clearance OptiFlex Pro B...

  • Page 51: Optiselect Pro Gm04

    Gun cable Threaded sleeve Powder hose connection Shaft 10 Powder hose quick release connection (grounded) Rear part with hook 11 Electrode rinsing air Remote control connection SuperCorona connection 12 Trigger Gun handle OptiSelect Pro GM04  51 OptiFlex Pro B...

  • Page 52: Available Accessories

    Multi-spray adapter – Rinsing module (with corresponding OptiStar control unit only) – Various adapters for connection to earlier generations of control units – Gloves, anti-static **for more information, see spare parts list 52  OptiSelect Pro GM04 OptiFlex Pro B...

  • Page 53: Technical Data

    85 °C (+185 °F) Protection type IP64 Approvals 0102 II 2 D PTB 19 ATEX 5001 Dimensions OptiSelect Pro GM04 Weight 550 g Processible powders OptiSelect Pro GM04 Plastic powder Metallic powder Enamel powder OptiSelect Pro GM04  53 OptiFlex Pro B...
  • Page 54 Rev. 00 03/19 54  OptiSelect Pro GM04 OptiFlex Pro B...

  • Page 55: 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  55 OptiFlex Pro B...
  • Page 56 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 56  Fault clearance OptiFlex Pro B...

  • Page 57: Optiflow Ig07

    CD. Structure Overall view Fig. 14 Check valve unit Injector housing (supplementary air) Release trigger Powder hose quick release Check valve unit connection (conveying air) Powder hopper connection OptiFlow IG07  57 OptiFlex Pro B...

  • Page 58: 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! 58  OptiFlow IG07 OptiFlex Pro B...

  • Page 59: Maintenance / Repairs

    Clean the injector body with compressed air which is free of oil and water. – Any contamination can be seen through the opening of the hopper fitting If the injector is severely fouled, it must be dismantled Maintenance / Repairs  59 OptiFlex Pro B...

  • Page 60: 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! ► Never remove the supporting ring! 60  Maintenance / Repairs OptiFlex Pro B...

  • Page 61: Changing The Cartridge

    Rev. 00 03/19 fig. 16 Connection/plug Filter element O-ring 3.1 Supporting ring Changing the cartridge Maintenance / Repairs  61 OptiFlex Pro B...
  • Page 62 Rev. 00 03/19 62  Maintenance / Repairs OptiFlex Pro B...

  • Page 63: Fault Clearance

    Conveying vacuum Increase the powder Gun achieving only too low quantity and/or total poor spray profile air volume on the control unit Cartridge worn, Replace or install the clogged or not cartridge. inserted Fault clearance  63 OptiFlex Pro B...
  • Page 64 Rev. 00 03/19 64  Fault clearance OptiFlex Pro B...

  • Page 65: 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  65 OptiFlex Pro B...

  • Page 66: Optiflex Pro B - Spare Parts List

    Rev. 00 03/19 OptiFlex Pro B – Spare parts list OptiStar CG21 gun control unit – complete (see corresponding operating manual) OptiSelect Pro GM04 Manual powder gun – complete (see corresponding user manual) OptiFlow IG07 injector – complete (see corresponding user manual) Pneumatic connection for supplementary air –...

  • Page 67: Optiflex Pro B - Spare Parts

    Rev. 00 03/19 OptiFlex Pro B – Spare parts fig. 17: Spare parts list  67 OptiFlex Pro B...

  • Page 68: Fluidizing/Suction Unit

    Quick release connection – NW5, Ø 6 mm 200 840 Nut with kink protection – M10x1 mm, Ø 6 mm 201 308 Plastic tube – Ø 6/4 mm, black 1001 973 * Please indicate length # Wearing part 68  Spare parts list OptiFlex Pro B...

  • Page 69: Fluidizing/Suction Tube - Spare Parts

    Rev. 00 03/19 Fluidizing/suction tube – spare parts fig. 18: Fluidizing/suction tube – spare parts Spare parts list  69 OptiFlex Pro B...

  • Page 70: 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. 19: Pneumatic group 70  Spare parts list OptiFlex Pro B...

  • Page 71: Powerclean Module Set

    Plastic tube – Ø 8/6 mm, black 103 152* O ring – Ø 16x2 mm, NBR70, anti-static (2x) (not shown) Cable tie (not shown) * Please indicate length # Wearing part fig. 20: PowerClean module set** Spare parts list  71 OptiFlex Pro B...

  • Page 72: Optistar Cg21 Gun Control Unit

    OptiStar CG21 gun control unit – complete, without item 4 1015 203 Front plate – complete, see corresponding spare parts list Enclosure Backplate – complete, see corresponding spare parts list Cover 1015 249 4 ––––– fig. 21 72  Spare parts list OptiFlex Pro B...

  • Page 73: Front Plate And Power Pack

    Front plate gasket 1015 236 Membrane keypad Spacer sleeve – Ø 3.6/7x5 mm Display 1015 220 Washer – Ø 3.2/7x0.5 mm Locknut – M3 Power pack – 24 VDC 1009 849 Fig. 22 Spare parts list  73 OptiFlex Pro B...

  • Page 74: Inside Back Plate

    1001 521 Fluidizing pad – 1/8" 237 264 Screw – M4x16 mm 1013 925 Plastic tube – Ø 8/6 mm 103 152* Motor throttle – complete 1008 012 * Please indicate length 74  Spare parts list OptiFlex Pro B...

  • Page 75: Inside Back Plate

    Rev. 00 03/19 Inside back plate fig. 23: OptiStar CG21 Spare parts list  75 OptiFlex Pro B...

  • Page 76: Connecting Material

    Mains cable – Schuko 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 76  Spare parts list OptiFlex Pro B...

  • Page 77: Connecting Material

    Rev. 00 03/19 Connecting material fig. 24 Spare parts list  77 OptiFlex Pro B...

  • Page 78: Optiselect Pro Gm04 - Spare Parts List

    O-ring for pos. 15 1000 822 # Threaded sleeve (see corresponding spare parts list) Nozzle (see corresponding spare parts list) Cable lock 1017 685 Screw – M3x20 mm 1017 674 Contact strip 1018 707 78  Spare parts list OptiFlex Pro B...
  • Page 79 Powder hose – Ø 10 mm (not shown) 1001 673*# Powder hose – Ø 11 mm (not shown) 105 139*# * Please indicate length # Wearing part fig. 25: OptiSelect Pro GM04 – spare parts Spare parts list  79 OptiFlex Pro B...

  • Page 80: 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. 26 80  Spare parts list OptiFlex Pro B...

  • Page 81: Supercorona

    Rev. 00 03/19 SuperCorona SuperCorona PC.. 1018 291# # Wearing part fig. 27 Spare parts list  81 OptiFlex Pro B...

  • Page 82: Accessories

    NF22 1008 145 Profiles/big flat NF40 parts (standard 1018 166 nozzle) NF40* 1018 165 NF24 1008 326 Large surfaces 1008 142 NF24* 1008 147 * not suitable for angled nozzles 82  Spare parts list OptiFlex Pro B...
  • Page 83 Threaded sleeve Deflectors Ø 16 mm NS04 Suitable for 331 341 large surfaces 1008 150 Ø 24 mm NS04 1008 152 331 333 1008 151 1007 229 Ø 32 mm 331 325 Spare parts list  83 OptiFlex Pro B...
  • Page 84 ► The extensions (150 mm/300 mm) may be connected TO ONLY ONE ADDITONAL extension (150 mm/300 mm), if necessary. 84  Spare parts list OptiFlex Pro B...
  • Page 85 NF26 1007 742 1007 740 Ø 16 mm Suitable for NS09 331 341 large 1008 259 surfaces NS09 Ø 24 mm 1008 258 1008 257 331 333 Ø 32 mm 331 325 Spare parts list  85 OptiFlex Pro B...
  • Page 86 * Please indicate length Other accessories 150 ml 500 ml Application cup 1004 552 1002 069 Gun extension cables L=6 m 1002 161 Gloves, anti-static (1 pair) 800 254 86  Spare parts list OptiFlex Pro B...

  • Page 87: Optiflow Ig07 - 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  87 OptiFlex Pro B...

  • Page 88: Optiflow Ig07 - Spare Parts

    Rev. 00 03/19 OptiFlow IG07 – spare parts fig. 28 88  Spare parts list OptiFlex Pro B...
  • Page 89 Fault clearance ....... 41, 47, 55, 63 Start-up ............23 Figure references in the text ......6 Storage ............35 Input keys and switches ........45 Technical Data ..........53 Intended use ............ 13 Maintenance ..........37, 59 Index  89 OptiFlex Pro B...
  • Page 90 Rev. 00...

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