En
Operating instructions and spare parts list
Manual coating equipment
OptiFlex 2 B
Translation of the original operating instructions
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Documentation OptiFlex 2 B
© Copyright 2010 ITW Gema 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 ITW Gema GmbH.
OptiTronic, OptiGun, EasyTronic, EasySelect, OptiFlow and
SuperCorona are registered trademarks of ITW Gema GmbH
OptiMatic, OptiMove, OptiMaster, OptiPlus, PowerClean, Precise Charge
Control (PCC), OptiSpray, MultiTronic and Gematic are trademarks of
ITW Gema 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 knowledge and belief, the information contained in this
publication was correct and valid on the date of publication. ITW Gema
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.
Printed in Switzerland
ITW Gema GmbH
Mövenstrasse 17
9015 St. Gallen
Switzerland
Phone: +41-71-313 83 00
Fax.: +41-71-313 83 83
E-Mail: info@itwgema.ch
Homepage: www.itwgema.ch
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OptiFlex 2 B Table of contents 1
Table of contents
General safety regulations 3
Safety symbols (pictograms) ................................................................................... 3
Conformity of use .................................................................................................... 8
Product-specific safety measures ........................................................................... 8
OptiFlex 2 B manual coating equipment .................................................... 8
About this manual 9
General information ................................................................................................ 9
Product description 11
Field of application ................................................................................................ 11
Utilization .................................................................................................. 11
Reasonably foreseeable misuse .............................................................. 12
Technical data ....................................................................................................... 12
Connectable guns .................................................................................... 12
Powder output (guide values) .................................................................. 12
Guide values for OptiFlex 2 CG09 with the OptiFlow IG06 injector ......... 13
Air flow rates ............................................................................................ 13
Electrical data .......................................................................................... 13
Pneumatic data ........................................................................................ 14
Dimensions .............................................................................................. 14
Processible powders ................................................................................ 14
Design and function .............................................................................................. 15
General view ............................................................................................ 15
Scope of delivery .................................................................................................. 16
OptiFlex 2 B ............................................................................................. 16
Typical properties - Characteristics of the functions ............................................. 16
Processing the powder directly from the original powder manufacturer's
container .................................................................................................. 16
Freely rotating head piece ....................................................................... 16
Start-up 17
Preparation for start-up ......................................................................................... 17
Basic conditions ....................................................................................... 17
Set-up .................................................................................................................... 17
Mounting instructions ............................................................................................ 18
Connection instructions ......................................................................................... 19
Initial start-up 21
Set head piece ...................................................................................................... 22
Setting the device type .......................................................................................... 22
Operation .............................................................................................................. 23
Coating ..................................................................................................... 23
Setting the background illumination ......................................................... 26
Color change ......................................................................................................... 27
General information ................................................................................. 27
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2 Table of contents OptiFlex 2 B
Shutdown .............................................................................................................. 30
Cleaning and maintenance 31
Daily maintenance ................................................................................................ 31
Weekly maintenance ............................................................................................ 31
If in disuse for several days .................................................................................. 31
Powder hose rinsing ................................................................................ 32
Cleaning ................................................................................................................ 32
Cleaning the fluidizing/suction unit .......................................................... 32
Cleaning the OptiFlex 2 GM03 manual powder gun ............................... 32
Maintenance and cleaning of the filter unit ........................................................... 33
Replacing the filter element ..................................................................... 33
Troubleshooting 35
General information .............................................................................................. 35
Spare parts list 37
Ordering spare parts ............................................................................................. 37
OptiFlex 2 B manual coating equipment – Spare parts ........................................ 38
OptiFlex 2 B manual coating equipment – Spare parts ........................................ 39
OptiFlex 2 B – Pneumatic group........................................................................... 40
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OptiFlex 2 B General safety regulations 3
General safety regulations
This chapter sets out the fundamental safety regulations that must be
followed by the user and any third parties 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)
The following warnings with their meanings can be found in the ITW
Gema operating instructions. The general safety precautions must also
be followed as well as the regulations in the operating instructions.
DANGER!
Danger due to live electricity 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
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4 General safety regulations OptiFlex 2 B
The OptiFlex 2 B Manual coating equipment is built to the latest
specification and conforms to the recognized technical safety regulations.
It 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 any such non-compliant use and the
user shall bear sole responsibility for such actions. ITW Gema GmbH
must be consulted prior to any use of the OptiFlex 2 B Manual coating
equipment for purposes or substances beyond those stipulated in our
guidelines.
Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of the conformity of 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.itwgema.ch.
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 exempts 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.
General
dangers
General
Information
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OptiFlex 2 B General safety regulations 5
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 ITW Gema spare parts should be used!
Repairs must only be carried out by specialists or by authorized ITW
Gema service centers. Unauthorized conversions and modifications can
lead to injuries and damage to the equipment and invalidate the ITW
Gema GmbH guarantee.
These general safety regulations must
be read and understood in all cases
prior to start-up!
The connecting 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.
All maintenance activities must take place when the powder spraying
equipment is switched off.
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
too.
The control units for the spray guns must be installed and used in
zone 22. Spray guns are allowed in zone 21.
Only original ITW 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 (UEG = max. permissible powder/air concentration). If the UEG is
not known, then a value of 10 g/m³ should be considered (see
EN 50177).
All unauthorized conversions and modifications to the electrostatic
spraying equipment 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 location.
Electrical
dangers
Explosive danger
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6 General safety regulations OptiFlex 2 B
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.
Grounding
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 (green/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!
Slipping
danger
No smoking or open
flames
Strict compliance
with grounding
requirements
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OptiFlex 2 B General safety regulations 7
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).
The operating personnel must wear electrically conductive 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
prior to start-up!
No flash
photography
Not safe for persons
with pacemakers
Separate from
power mains before
maintenance or
repairs
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8 General safety regulations OptiFlex 2 B
Conformity of use
1. 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.
2. Any other use is considered non-compliant. The manufacturer
shall not be liable for damages resulting from such use; the user
bears sole responsibility for such actions. ITW Gema GmbH
must be consulted before OptiFlex 2 B manual coating
equipment is used for any other purposes or substances beyond
those indicated here.
3. Observance of the operating, service and maintenance
instructions specified by the manufacturer is also part of
conformity of use. The OptiFlex 2 B manual coating equipment
should only be used, maintained and started up by trained
personnel informed and familiar with the possible hazards
involved.
4. Start-up (i.e. operation of its intended use) is not allowed
until it has been established that the OptiFlex 2 B manual coating
equipment has been installed and wired according to the EU
Machinery Directive (2006/42/EC). EN 60204-1 (machine safety)
must also be observed.
5. Unauthorized modifications to the OptiFlex 2 B manual coating
equipment exempts the manufacturer from any liability from
resulting damage.
6. The relevant accident prevention regulations, as well as other
generally recognized safety regulations, occupational health and
structural regulations are to be observed.
7. Furthermore, the country-specific safety regulations also must be
observed.
Product-specific safety measures
- Installation work performed by the customer must be carried
out according to local regulations.
- All components must be grounded according to the local
regulations before start-up.
OptiFlex 2 B manual coating equipment
The OptiFlex 2 B manual coating equipment is a constituent part of the
equipment and is therefore integrated in the system's safety concept.
If it is to be used in a manner outside the scope of the safety concept,
then corresponding measures must be taken.
Note:
For further security information, see the more detailed ITW Gema
safety regulations!
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OptiFlex 2 B About this manual 9
About this manual
General information
This operating manual contains all important information required to work
with the OptiFlex 2 BOptiFlex 2 B-en.doc manual coating equipment. It
will safely guide you through the start-up process and give you
references and tips for the optimal use of your new powder coating
system.
Information about the functionality of the individual system components booth, gun control unit, manual gun or powder injector - should be
referenced to their enclosed corresponding documents.
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OptiFlex 2 B Product description 11
Product description
Field of application
The OptiFlex 2 B (with powder box) manual coating equipment is
exclusively intended for electrostatic coating using organic powders (For
more on this please also review chapter "Technical Data").
Any other use is considered non-compliant. The manufacturer is not
responsible for any incorrect use, and any associated risks are assumed
by the user alone.
For a better understanding of the interrelationships in powder coating, it
is recommended that the operating instructions for all other components
be read as well, so as to be familiar with their functions too!
OptiFlex 2 B manual coating equipment
Utilization
The electrostatic OptiFlex 2 B manual coating equipment with the
OptiFlex 2 GM03 manual powder gun is ideally suited for manual coating
of objects.
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12 Product description OptiFlex 2 B
Reasonably foreseeable misuse
- Operation without the proper training
- Use with insufficient compressed air quality and grounding
- Use in connection with unauthorized coating devices or
components
Technical data
Connectable guns
OptiFlex 2 B connectable
OptiFlex 2 GM03 yes
OptiSelect GM02 contact Gema
OptiGun GA02 contact Gema
PG3-E**
contact Gema
TriboJet*
yes
* The gun type must be configured (For more on this, please see the
operating instructions for the OptiFlex 2 CG09 manual gun control unit).
The Tribo gun the gun is not type approved (ATEX).
** Only for enamel powder, the gun is not type approved (ATEX).
Warning:
The OptiFlex 2 B manual coating equipment can only be used with
the specified gun types!
Powder output (guide values)
General conditions for the OptiFlow Injector
Powder type Epoxy/polyester
Powder hose length (m)
6
Powder hose Ø (mm)
10
Power hose type POE with guide strips
Input pressure (bar)
5,5
Conveying air nozzle Ø (mm)
1,6
Correction value C0 Powder output zeroing adjustment
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OptiFlex 2 B Product description 13
Guide values for OptiFlex 2 CG09 with the
OptiFlow IG06 injector
All values in these tables are guide values. Differing environmental
conditions, wear and different powder types can affect the table values.
Total air
3 Nm³/h 4 Nm³/h 5 Nm³/h
Powder output (g/min)
Powder output (%)
20
85 100 120
40
150 185 210
60
210 255 280
80
270 320 350
100
300 360 395
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.
OptiFlex 2 B Range
Factory
setting
Flow rate - fluidizing air
- OptiFlex B 0-1.0 Nm³/h 0.1 Nm³/h
Electrode rinsing air flow rate 0-3.0 Nm³/h 0.1 Nm³/h
Flow rate total air (at 5.5 bar) 1.8-6.5 Nm³/h
Note:
The total air consumption for the device is determined
based on the 3 configured air values.
These values apply for an internal control pressure of 5.5 bar!
Electrical data
OptiFlex 2 B
Nominal input voltage 100-240 VAC
Frequency 50 -60 Hz
Connected load (without vibrator) 140 VA
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
output)
110/230 VAC
max. 100 W
Connection for rinsing function (valve)
24 VDC
max. 3 W
Temperature range
0°C - +40°C
(+32°F - +104°F)
Max. operating temperature 85°C (+185°F)
Approvals pending
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14 Product description OptiFlex 2 B
Pneumatic data
OptiFlex 2 B
Max. input pressure 10 bar
Min. input pressure 6 bar
Input pressure (Dynamic based on pressure
regulator setting)
5.5 bar / 80 psi
Max. water vapor content of the compressed
air
1.3 g/m³
Max. oil vapor content of the compressed air 0.1 mg/m³
Max. compressed air consumption 8 Nm³/h
Dimensions
OptiFlex 2 B
Width 460 mm
Depth 862 mm
Height 1105 mm
Weight 42 kg
Processible powders
OptiFlex 2 B
Plastic powder yes
Metallic powder yes
Enamel powder no
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OptiFlex 2 B Product description 15
Design and function
General view
OptiFlex 2 B manual coating equipment - Structure
1 OptiFlex 2 CG09 control unit 10 Filter unit
2 OptiFlex 2 GM03 manual powder gun 11 Gun holder
3 OptiFlow injector 12 Hose holder
4 Mobile frame with hand rail 13 PowerClean module
5 Fluidizing/suction unit 14 Shelf
6 Vibrating table 15 Rubber wheel
7 Powder box 16 Swivel wheel
8 Swivel arm with guide sleeve
OptiFlex 2 GM03 manual powder gun
All information about the OptiFlex 2 CM03 manual powder gun can be
found in the documentation for that equipment (enclosed with this
manual)!
OptiFlex 2 CG09 control unit
All information about the OptiFlex 2 CG09 manual gun control unit can
found in the documentation for that equipment (enclosed with this
manual)!
OptiFlow injector
All information about the OptiFlow injector can be found in the
corresponding enclosed documentation!
2
1
3
13
5
7
16
4
8
6
15
11
12
14
10
V 05/11
16 Product description OptiFlex 2 B
Scope of delivery
OptiFlex 2 B
- OptiFlex 2 CG09 control unit in a metal case with power
supply cable
- mobile trolley with a gun/hose support
- vibrating base and a fluidizing/suction unit
- plug-in OptiFlow injector
- OptiFlex 2 CM03 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
OptiFlex 2 CM03 manual powder gun)
- Pneumatic hoses for conveying air (red), supplementary
air (black), fluidizing air (black) and rinsing air (black)
- Operating manual
- Short instructions
Typical properties - Characteristics of the functions
Processing the powder directly from the original
powder manufacturer's container
The OptiFlex 2 B manual coating equipment allows for powder to be
processed directly out of the original powder manufacturer's container. A
titled vibrating floor has been included to ensure that the powder
container empties itself completely.
Freely rotating head piece
The OptiFlex 2 B manual coating equipment features a freely rotating and
lockable head piece for more ergonomic operation and configuration.
Freely rotating head piece
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OptiFlex 2 B Start-up 17
Start-up
Preparation for start-up
Basic conditions
When starting up the OptiFlex 2 manual coating unit, the following
general conditions impacting the coating results must be taken into
consideration:
- Manual coating equipment is set up properly
- Gun control unit correctly connected
- Gun correctly connected
- Corresponding power and compressed air supply available
- Powder preparation and powder quality
Set-up
The OptiFlex 2 B manual coating equipment should always be set up
vertically on a flat surface.
WARNING
The manual coating equipment must not under any circumstances
be set up near a heat source (such as an enameling furnace) or an
electromagnetic source (such as a control cabinet).
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18 Start-up OptiFlex 2 B
Mounting instructions
The OptiFlex 2 B manual coating equipment must be set up in
accordance with the setup and connecting instructions (included with
delivery).
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OptiFlex 2 B Start-up 19
Connection instructions
Connection instructions - overview
The OptiFlex 2 B manual coating equipment must be connected in
accordance with the setup and connection instructions (Please also
review the operating instructions for the OptiFlex 2 CG09 manual gun
control unit).
1.
2.
Note:
Use clamp to connect grounding cable to the cabin or the
suspension arrangement. Check ground connections with Ohm
meter and ensure 1 MOhm or less!
Maintenance unit
Injector
Gun
PowerClean module
Fluidizing/suction unit
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20 Start-up OptiFlex 2 B
3. 4.
5.
6.
7.
8.
9.
10.
Note:
The compressed air must be free of oil and water!
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OptiFlex 2 B Initial start-up 21
Initial start-up
Note:
If a malfunction occurs, see the troubleshooting guide, as well as
the gun control unit operating manual!
Note:
The remainder of the start-up procedure for the OptiFlex 2 GM03
manual powder gun is explicitly described in the operating
instructions for the OptiFlex 2 CG09 manual powder gun control
unit (chapter "Initial start-up" and "Daily start-up")!
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22 Initial start-up OptiFlex 2 B
Set head piece
1. 2.
3.
Setting the device type
Note:
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 OptiFlex 2 CG09 manual gun
control unit)!
NOTE!
The manual gun control unit always starts up to the last configured
settings.
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OptiFlex 2 B Initial start-up 23
Operation
Coating
1. Turn on the gun control unit with the ON key
The displays illuminate and the control unit is ready for operation
2. Swivel aside the fluidizing/suction unit
3. Place the open powder container on the vibrating table
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
complicated parts
overcoat
The arrow above the desired button lights up
OR
7. Press
program key
a) Select desired program (01-20)
b) Change coati ng parameters as required
Note:
Programs 01-20 are preset at the factory but can be modified at any
time, after which they are automatically stored.
Description Presetting
Powder output
50%
Total air
4.0 Nm³/h
High voltage 80 kV
Spray current
80 µA
Electrode rinsing air
0.1 Nm³/h
Fluidizing air 0.1 Nm³/h (for OptiFlex-B and S)
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24 Initial start-up OptiFlex 2 B
8. Setting the total air volume
correct powder cloud too little total air
Note:
A total air volume of 4 Nm³/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)
or
much powder little powder
Note:
To achieve maximum efficiency, we recommend avoided an overly
high powder volume where possible! Für den Anfang empfiehlt sich
die Standardeinstellung von 50% und eine Gesamtluftmenge von 4
Nm³/h. Die Gesamtluftmenge wird dabei automatisch von der
Steuerung konstant gehalten
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!
V 05/11
OptiFlex 2 B Initial start-up 25
10. Setting the electrode rinsing air
a) Press the key
The second display level will be shown
b)
too much electrode rinsing air
11. Setting the fluidization
a) Press the key
The second display level will be shown
b)
c) Check the powder fluidization 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.
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
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.
a)
- The LCD segments begin to move on the CG09 display
approx.
0.1 Nm³/h
approx.
0.5 Nm³/h
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26 Initial start-up OptiFlex 2 B
Note:
The PowerClean function can be stopped as required using the P
key.
b)
Procedure Effect
automatic
- 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.
manual
- The operator controls the number and length of the
PowerClean impulse by pressing the pistol trigger a
second time
After completion of the PowerClean procedure, the controller switches
back to coating mode.
Setting the background illumination
1. Press key
The display switches to the following level:
2.
Select the desired brightness
= automatically
= manually
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OptiFlex 2 B Initial start-up 27
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).
1.
2.
3. 4.
5.
6.
7.
8.
9.
10.
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28 Initial start-up OptiFlex 2 B
11. 12.
13.
14.
15.
16.
16.
17.
18.
19.
20.
21.
22.
23.
Remove and clean the nozzle
purge gun using air
V 05/11
OptiFlex 2 B Initial start-up 29
24. 25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
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30 Initial start-up OptiFlex 2 B
Shutdown
1. Release gun trigger
2. Switch off the control unit
Note:
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
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OptiFlex 2 B Cleaning and maintenance 31
Cleaning and maintenance
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 OptiFlex 2 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. Separate from power mains
2. Clean the coating equipment
3. Turn off the compressed air main supply
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32 Cleaning and maintenance OptiFlex 2 B
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
3. Blow through the hose manually with a compressed air gun
4. Connect the powder hose again to the hose connection on the
injector
Cleaning
Cleaning the fluidizing/suction unit
1. Remove the 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
5. Clean the injector (see therefore the injector user manual)
6. Clean rinsing module
7. Reassemble the individual parts
Cleaning the OptiFlex 2 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 must be free of oil and water!
Daily:
1. Blow off the 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
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OptiFlex 2 B Cleaning and maintenance 33
Note:
Please also review the user manual for the OptiFlex 2 GM03 manual
powder gun!
Maintenance and cleaning of the filter unit
The filter unit on the OptiFlex B manual coating equipment measures and
cleans the compressed air. This is where the equipment's main
compressed air connection is located.
Replacing the filter element
Procedure:
1. Unscrew the filter glass on the filter unit
2. Loose the cap screw
3. Remove the complete filter element
4. Replace the filter element
5. Clean the filter glass on the inside and install it again
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OptiFlex 2 B Troubleshooting 35
Troubleshooting
General information
Note:
Prior to any troubleshooting measures, always check whether the
equipment parameters (P0) as configured in the control unit are
correct (See operating instructions for the OptiFlex 2 CG09 manual
gun control unit, Chapter "Initial Start-up – Setting Equipment
Type")
Fault Causes Troubleshooting
Control unit displays
remain dark, although
the control unit is
switched on
Control unit is not
connected to the mains
Connect the equipment
with the mains cable
Power pack fuse
defective
Replace the fuse
Power pack defective
Contact local Gema
representative
The gun does not
spray powder,
although the control
unit is switched on and
the gun trigger is
pressed
Compressed air not
present
Connect the equipment
to the compressed air
Injector, throttle motor or
nozzle on injector,
powder hose or powder
gun are clogged
Clean the corresponding
part
Insert sleeve in the
injector is clogged
Replace
Insert sleeve is not
installed
Mount insert sleeve
Fluidization not running see below
Total air incorrectly
configured
Set total air correctly
(Default value 4 Nm³/h)
Main valve defective Replace main valve
Gun LED remains
dark, although the gun
is triggered
Gun not connected Connect the gun
Gun plug, gun cable or
gun cable connection
defective
Contact local Gema
representative
Remote control on
powder gun defective
Contact local Gema
representative
Powder does not
adhere to object,
The objects are
improperly or
Check grounding,
reground at better
V 05/11
36 Troubleshooting OptiFlex 2 B
Fault Causes Troubleshooting
although the gun is
triggered and sprays
powder
insufficiently grounded quality
High voltage and current
deactivated
Press the selection key
(application key)
High voltage cascade
defective
Contact local Gema
representative
The powder is not
fluidized
Compressed air not
present
Connect the equipment
to the compressed air
Fluidizing air is set too
low on the control unit
Set the fluidizing air
correctly
Throttle motor defective
Contact local Gema
representative
No electrode rinsing air
Rinsing air throttle motor
defective
Contact local Gema
representative
Vibrator not functioning
Vibrator/condenser
broken
Contact local Gema
representative
Vibrator not plugged in plug in
Incorrect equipment
type configured
Configure parameter P0
(See operating
instructions for the
OptiFlex 2 CG09
manual gun control unit,
Chapter "Initial Start-up
– Setting Equipment
Type")
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OptiFlex 2 B Spare parts list 37
Spare parts list
Ordering spare parts
When ordering spare parts for powder coating equipment, please in dicate
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 - Ø 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:
Ø 8/6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d)
WARNING!
Only original ITW 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 ITW Gema
guarantee conditions!
V 05/11
38 Spare parts list OptiFlex 2 B
OptiFlex 2 B manual coating equipment – Spare parts
1 CH09 gun control unit - complete (see corresponding operating manual) 1007 018
2 GM03 manual powder gun - complete (see corresponding user manual) 1008 070
3 IG06 injector - complete (see corresponding user manual) 1007 780
4
Pneumatic connection for conveying air - complete (incl. Pos. 4.1, 4.2, 4.3) 1008 030
4.1 Quick release connection - NW5, Ø 8 mm, red 261 645
4.2 Nut with kink protection – M12x1 mm, Ø 8 mm 201 316
4.3 Plastic tube - Ø 8/6 mm, red 103 500*
5
Pneumatic connection for supplementary air - complete (incl. Pos. 5.1, 5.2 and 5.3) 1008 029
5.1 Quick release connection - NW5, Ø 8 mm, black 261 637
5.2 Nut with kink protection – M12x1 mm, Ø 8 mm 201 316
5.3 Plastic tube - Ø 8/6 mm, black 1008 038*
6 Rinsing module – complete (See operating instructions OptiFlex 2 GM03 manual
powder gun)
1007 362
7
Pneumatic connection for conveying air - complete (incl. Pos. 7.1 and 7.2) 1008 032
7.1 Quick release connection - NW5, Ø 8 mm 1008 027
7.2 Plastic tube - Ø 8/6 mm, black 103 152*
8 Fluidizing/suction unit - complete 1007 509
9
Pneumatic connection for conveying air - complete (incl. Pos. 9.1, 9.2 and 9.3) 1008 031
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 Pneumatic group - complete (see corresponding spare parts list)
11 Quick release connection - NW7, 8-Ø 10- Ø 26 mm 239 267
12 Rubber damper - Ø 20x25 mm, M6/2a, 43sh 246 000
13 Hexagon shakeproof nut - M6 244 430
14 Powder hose – Ø 15/10 mm, 6m 1001 673
15 Spare parts kit – MB03, consisting of: 1007 147
Insert sleeve IG06 - complete 1006 485
O-ring - Ø 16x2 mm 1007 794
O-ring – Ø 20x3 mm 1007 121
Fuse - 0.1 AT 229 520
Fuse - 2 AT 221 872
Cable tie - L=100x2.5 mm 200 71 9
16 Brief instructions 1007 143
17 Operating manual 1007 141
* Please indicate length
V 05/11
OptiFlex 2 B Spare parts list 39
OptiFlex 2 B manual coating equipment – Spare parts
OptiFlex 2 B manual coating equipment – Spare parts
15
10
14
17
16
12, 13
2
1
3
11
6
8
5
4
9
7
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40 Spare parts list OptiFlex 2 B
OptiFlex 2 B – Pneumatic group
Pneumatic group - complete 1007 120
1 Filter cartridge - 20 µm 1007 325
OptiFlex 2 B – Pneumatic group
1
V 05/11
OptiFlex 2 B Spare parts list 41
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