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Gema OptiFlex Pro F User Manual

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

Table of Contents

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Gema OptiFlex Pro F Specifications

General IconGeneral
ApplicationPowder Coating
Spray Tip SizeVarious sizes available
TypeElectrostatic Powder Coating
Voltage100 kV
Control SystemDigital
TechnologyDigital Valve Control
Control UnitOptiStar
Powder FeedHopper
Hose Length5 m

Summary

About these instructions

General information

Provides essential operational information for the OptiFlex Pro F Spray equipment.

Keeping the Manual

Instructions on how to store and refer to the manual for future use.

Safety symbols (pictograms)

Explains the meaning of various safety warning symbols used in the manual.

Structure of Safety Notes

Details the components and structure of safety notes within the manual.

Presentation of the contents

Outlines how the manual's content is organized for user reference.

Figure references in the text

Explains the use of cross-references to figures within the descriptive text.

Safety

General information

Provides essential safety regulations and adherence requirements for product operation.

Basic safety instructions

Details fundamental safety guidelines for the proper and safe use of the product.

Product specific security regulations

Outlines safety regulations specific to the product's integration into equipment systems.

General dangers

Highlights potential general dangers associated with product operation and modifications.

Electrical danger

Details risks and precautions related to electrical connections and maintenance.

Explosion hazard

Addresses risks of explosion due to dust concentration and necessary safety measures.

Slip hazard

Warns about potential slipping hazards from powder on the floor.

Static charges

Explains consequences of static charges and the importance of proper grounding.

Grounding

Provides detailed instructions and requirements for proper electrical grounding procedures.

Smoking and open flames

Prohibits smoking and open flames in the vicinity of the system.

Stay for persons with cardiac pacemakers

Advises persons with pacemakers to avoid areas with high voltage or electromagnetic fields.

Photographing with flashlight

Warns against using flash photography due to potential interference with safety devices.

Maintenance works

Details precautions for maintenance, including disconnecting power and required PPE.

Product description

Intended use

Specifies the intended application of the coating equipment with organic powders.

Versions

Describes the different available versions of the manual coating equipment.

Reasonably foreseeable misuse

Lists foreseeable misuse scenarios to avoid for safe and proper operation.

Structure

Provides an overview of the equipment's structure and component identification.

Scope of delivery

Lists all components included in the scope of delivery for the equipment.

Typical characteristics – properties of the functions

Details the key features and functional properties of the coating equipment.

Technical Data

Connectable guns

Lists the types of guns that can be connected to the control unit.

Electrical data

Provides detailed electrical specifications including voltage, current, and power.

Pneumatic data

Details pneumatic requirements such as air connection, pressure, and vapor content.

Dimensions

Specifies the physical dimensions (width, depth, height, weight) of the equipment.

Processible powders

Indicates the types of powders (plastic, metallic, enamel) that can be processed.

Powder output (reference values)

Provides reference values for powder output based on conveying and suction hose specifications.

Air flow rates

Details the various air flow rates for fluidizing, rinsing, transport, and spraying.

Environmental conditions

Specifies the operating environmental conditions like temperature, humidity, and altitude.

Sound pressure level

States the sound pressure level measured during normal operation.

Rating plate

Describes the information found on the equipment's rating plate.

Assembly / Connection

Set-up

Provides guidelines for the correct vertical placement and environmental setup of the equipment.

Assembly guide

Refers to the included instructions for setting up and connecting the manual coating equipment.

Connection instructions

Details how to connect various cables and hoses for the control unit and application pump.

Set head piece

Provides step-by-step instructions for setting the gun's head piece.

Start-up

Preparation for start-up

Lists essential basic conditions that must be met before starting up the equipment.

Initial start-up

Guides through the initial startup procedure and troubleshooting for malfunctions.

Setting the device type

Explains how to set the device type parameter for correct system operation.

Operation

Select predefined operating mode (Preset mode)

Describes how to select and use predefined operating modes for coating.

Starting the individual adjustable programs

Explains how to start and manage individual adjustable programs for coating.

Setting powder output and powder cloud

Details how to adjust powder output and powder cloud based on selected parameters.

Setting the spraying air

Guides on how to adjust spraying air based on transport air and total air volume.

Setting the electrode rinsing air

Explains how to adjust the electrode rinsing air for optimal nozzle performance.

Cleaning mode

Describes the cleaning mode and its programs for blowing off powder accumulations.

Activating the cleaning function

Provides steps for activating the automated cleaning function of the equipment.

Pinch valve diagnostic

Details the procedure for performing a pinch valve diagnostic to maintain quality.

Setting the background illumination

Explains how to adjust the background illumination brightness of the control unit display.

Color change

Describes the process for performing an 'extreme' color change (light to dark).

Decommissioning / Storage

Shutdown

Outlines the correct procedure for safely shutting down the equipment.

If in disuse for several days

Provides instructions for short-term shutdown and preparation for inactivity.

Storage conditions

Specifies the required environmental and physical conditions for safe storage.

Maintenance during storage

Details maintenance tasks, schedule, and works required during storage periods.

Maintenance / Repairs

General information

Emphasizes the importance of cleaning and maintenance for product lifespan and quality.

Interval

Defines the frequency for maintenance tasks, including daily and weekly checks.

If in disuse for several days

Provides instructions for equipment preparation during extended periods of non-use.

Powder hose rinsing

Details the procedure for rinsing the powder hose during longer downtimes.

Gun maintenance

Outlines minimum maintenance requirements for the powder gun.

Maintenance of the filter unit

Explains the function of the filter unit and how to replace its filter element.

Cleaning

Gun cleaning

Provides detailed instructions and precautions for cleaning the powder gun.

Cleaning the powder container

Details the procedure for cleaning the powder container, emphasizing no solvents/water.

Repair work

States that repairs must be performed by authorized service workshops.

Periodic checks

Describes periodic checks of cables, hoses, and plugs for safety and integrity.

Fault clearance

H11 (Help code on control unit)

Guides troubleshooting for the H11 help code displayed on the control unit.

Control unit displays remain dark, although the control unit is switched on

Provides causes and corrective actions for a dark control unit display.

Gun LED remains dark, although the gun is triggered

Lists causes and solutions for a non-illuminated gun LED during triggering.

Powder does not adhere to object, although the gun is triggered and sprays powder

Addresses issues with powder adhesion, including grounding and high voltage settings.

Gun achieving only poor spray profile

Details causes and solutions for a poor spray profile from the gun.

No electrode rinsing air

Offers corrective actions when there is no electrode rinsing air.

The powder is not fluidized

Explains how to troubleshoot issues with powder fluidization.

Powder flows out of the powder hopper

Addresses causes and solutions for powder flowing out of the hopper.

Disposal

Introduction

Introduces the procedures and requirements for product disposal.

Requirements on personnel carrying out the work

Specifies who is responsible for carrying out the disposal process.

Disposal regulations

Outlines the legal and environmental regulations that must be followed during disposal.

Materials

Guides on sorting materials for proper disposal collection.

Spare parts list

Ordering spare parts

Provides instructions and necessary information for ordering spare parts.

OptiFlex Pro F Spray – Spare parts list

Lists all available spare parts for the OptiFlex Pro F Spray equipment.

OptiFlex Pro F Spray – Spare parts

Visual representation and numbering of spare parts for the OptiFlex Pro F Spray.

Powder hopper HF05-50 Spray – Spare parts list

Lists all available spare parts for the HF05-50 Powder hopper.

Powder hopper HF05-50 Spray – Spare parts

Visual representation and numbering of spare parts for the HF05-50 Powder hopper.

Diffuser (OptiSelect)

Diffuser - complete

Lists and details the complete spare parts for the OptiSelect diffuser.

Pneumatic group

Pneumatic group - complete

Lists and details the complete spare parts for the pneumatic group.

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