Gema OptiSelect GM03 Operating Instructions And Spare Parts List
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Gema OptiSelect GM03 Operating Instructions And Spare Parts List

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EN
Rev. 01
1011 454
Operating instructions and Spare parts list
Manual gun
OptiSelect GM03
Translation of the original operating instructions

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Summary of Contents for Gema OptiSelect GM03

  • Page 1 Rev. 01 1011 454 Operating instructions and Spare parts list Manual gun OptiSelect GM03 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

    Powder hose quick release connection ........... 17 Connection for SuperCorona Ring ............17 Assembly / Connection Connecting the gun ....................19 Start-up Preparation for start-up ..................21 Basic conditions ..................21 Initial start-up ......................22 Table of contents  3 OptiSelect GM03...
  • Page 4 Disposal regulations ................37 Materials ....................37 Spare parts list Ordering spare parts ..................... 39 OptiSelect GM03 – Spare parts list ..............40 PowerClean™ module (Option)................42 SuperCorona ......................43 Accessories ......................44 Flat jet nozzles – overview (wearing parts) ..........44 Round jet nozzle –...

  • Page 5: About These Instructions

    General information This operating manual contains all important information which you require for the working with the OptiSelect GM03. 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: Structure Of Safety Notes

    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 OptiSelect GM03...

  • 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

    The installation work to be done by the customer must be carried out according to local regulations. – It must be ensured, that all components are earthed according to the local regulations before start-up. For further security information, see the more detailed Gema safety regulations! 8  Safety OptiSelect GM03...

  • Page 9: 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  9 OptiSelect GM03...

  • Page 10: Reasonably Foreseeable Misuse

    Rev. 01 08/16 Reasonably foreseeable misuse – Use with insufficient compressed air quality – Input pressure too low Technical Data Electrical data OptiSelect GM03 Nominal input voltage eff. 10 V Frequency 18 kHz (average) Nominal output voltage 100 kV negative (optional...

  • Page 11: Structure

    Spray nozzle system 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 Product description  11 OptiSelect GM03...

  • Page 12: Operating Elements

    Rinsing air hose (6 m)  Flat jet nozzle NF20, complete (incl. electrode holder)  Flat jet nozzle NF21  Cable tie with Velcro closure  Gun cleaning brush  Spare parts kit  Operating manual 12  Product description OptiSelect GM03...

  • Page 13: Available Accessories

    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 Product description  13 OptiSelect GM03...

  • Page 14: Supercorona Ring

    SuperCorona assembly Before fitting the SuperCorona ring, make sure that the connection and the plug-in connector are free from grease and powder, otherwise the electric contact cannot be guaranteed. 14  Product description OptiSelect GM03...

  • Page 15: Principle Of Operation

    (see the operating manual of the gun control unit). The functions of the spray nozzles are described in the corresponding section of this manual. Product description  15 OptiSelect GM03...

  • Page 16: Flat Jet Nozzle With Vented Central Electrode

    Fig. 8 Since powder can accumulate on the baffle plate, it must be rinsed with compressed air. The electrode rinsing air (S) adjustment on the gun control unit is described in the corresponding operating manual. 16  Product description OptiSelect GM03...

  • Page 17: Typical Characteristics - Properties Of The Functions

    Powder hose quick release connection – Quick and simple connection and disconnection from powder hose and application cup Connection for SuperCorona Ring – Quick and simple connection and disconnection of the SuperCorona ring Product description  17 OptiSelect GM03...
  • Page 18 Rev. 01 08/16 18  Product description OptiSelect GM03...

  • Page 19: Assembly / Connection

    Velcro strips (included) Connect the gun cable plug to the socket 2.3 on the rear side of the control unit Connect electrode rinsing air hose to coupling 1.4 Connect powder hose to injector Assembly / Connection  19 OptiSelect GM03...
  • Page 20 Rev. 01 08/16 fig. 9 Maintenance unit PowerClean™ module Injector (Option) Fluidizing air hose 20  Assembly / Connection OptiSelect GM03...

  • Page 21: Start-Up

    When starting up the gun control unit, the following general conditions impacting the coating results must be taken into consideration: – Gun correctly connected – Gun control unit correctly connected – Corresponding power and compressed air supply available – Powder preparation and powder quality OK Start-up  21 OptiSelect GM03...

  • Page 22: Initial Start-Up

    Fig. 10 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")! 22  Start-up OptiSelect GM03...

  • Page 23: Operation

    Setting the total air volume 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 Operation  23 OptiSelect GM03...

  • Page 24: Setting The Electrode Rinsing Air

    Check fluidization of the powder in the powder container Point the gun into the booth, switch the gun on and visually check the powder output Setting the electrode rinsing air Press the key. The second display level will be shown. 24  Operation OptiSelect GM03...

  • Page 25: Rinsing Mode

    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. Detach the injector Operation  25 OptiSelect GM03...
  • Page 26 After completion of the PowerClean procedure, the controller switches back to coating mode. 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). 26  Operation OptiSelect GM03...

  • Page 27: Activate/Deactivate The Program Change Function Via Remote Control

    Activate/deactivate the program change function on the gun control unit Hold key pressed Press the – The display flashes once, and the program change function is activated/deactivated Operation  27 OptiSelect GM03...
  • Page 28 Rev. 01 08/16 28  Operation OptiSelect GM03...

  • Page 29: 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  29 OptiSelect GM03...

  • Page 30: 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. 30  Decommissioning / Storage OptiSelect GM03...

  • Page 31: Maintenance / Repairs

    Gun cleaning ATTENTION Impermissible solvents The following solvents may not be used to clean the gun: ► Ethylene chloride, acetone, ethyl acetate, methyl ethyl ketone, methylene chloride, premium gasoline, turpentine, tetrachloromethane, toluene, trichloroethylene, xylene! Maintenance / Repairs  31 OptiSelect GM03...

  • Page 32: Cleaning The Spray Nozzle

    If sinterings should have formed, then they have to be removed! Monthly Check spray nozzle for wear The flat jet nozzle is to be replaced, if: – the spray pattern is no longer a regular oval 32  Maintenance / Repairs OptiSelect GM03...

  • Page 33: Replacing Parts

    Except for the replacement of possible defective parts, there are very few repairs to be made. The replacement of the cascade and the repair of the powder gun cable connection is only permitted by an authorized Gema Service center! –...
  • Page 34 Rev. 01 08/16 34  Maintenance / Repairs OptiSelect GM03...

  • Page 35: Fault Clearance

    Causes Corrective action H11 (Help code on control Gun not connected Connect the gun unit) Gun plug or gun cable defective Contact local Gema representative Remote control on powder gun Contact local Gema defective representative Gun LED remains dark, High voltage adjustment is set...
  • Page 36 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 36  Fault clearance OptiSelect GM03...

  • Page 37: 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 38 Rev. 01 08/16 38  Disposal OptiSelect GM03...

  • Page 39: 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  39 OptiSelect GM03...

  • Page 40: Optiselect Gm03 - Spare Parts List

    – 6 m, rinsing air hose – 6 m, flat jet nozzle, 1008 073 brush and parts kit, without powder hose Manual powder gun shaft OptiSelect GM03 (incl. cascade) with: Gun cable 2 m, negative polarity (–) 1007 971 Gun cable 6 m, negative polarity (–)
  • Page 41 Powder hose – Ø 10 mm (not shown) 1001 673*# Powder hose – Ø 11 mm (not shown) 105 139*# * Please indicate length # Wearing part fig. 11: OptiSelect GM03 – spare parts Spare parts list  41 OptiSelect GM03...

  • Page 42: 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. 12 42  Spare parts list OptiSelect GM03...

  • Page 43: Supercorona

    Rev. 01 08/16 SuperCorona SuperCorona PC05 1008 165# # Wearing part Fig. 13 Spare parts list  43 OptiSelect GM03...

  • Page 44: Accessories

    NF21 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 44  Spare parts list OptiSelect GM03...

  • Page 45: Round Jet Nozzle - Overview (Wearing Parts)

    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  45 OptiSelect GM03...

  • Page 46: Gun Extensions

    It is not permitted to connect more than two extensions together, in order to prevent the gun from being damaged by arising leverage force. ► The extensions (150 mm/300 mm) may be connected TO ONLY ONE ADDITONAL extension (150 mm/300 mm), if necessary. 46  Spare parts list OptiSelect GM03...

  • Page 47: Spray Nozzles For Extensions - Overview (Wearing Parts)

    1007 740 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  47 OptiSelect GM03...

  • Page 48: Powder Hoses - Overview

    * 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 48  Spare parts list OptiSelect GM03...
  • Page 49 Safety symbols ..........5 Spare parts list ..........39 Start-up ............21 Fault clearance ..........35 Storage ............29 Figure references in the text ......6 Storage conditions ........... 29 Intended use ............9 Technical Data ..........10 Index  49 OptiSelect GM03...
  • Page 50 Rev. 01...

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