Gema OptiSelect Pro GM04 Operating Instructions And Spare Parts List
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Gema OptiSelect Pro GM04 Operating Instructions And Spare Parts List

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EN
Rev. 01
1011 543
Operating instructions and Spare parts list
Manual gun
OptiSelect Pro GM04
Translation of the original operating instructions

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Summary of Contents for Gema OptiSelect Pro GM04

  • Page 1 Rev. 01 1011 543 Operating instructions and Spare parts list Manual gun OptiSelect Pro GM04 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 Pro GM04...
  • Page 4 Disposal regulations ................39 Materials ....................39 Spare parts list Ordering spare parts ..................... 41 OptiSelect Pro GM04 – spare parts list ..............42 PowerClean™ module (Option)................44 SuperCorona ......................45 Accessories ......................46 Flat jet nozzles – overview (wearing parts) ..........46 Round jet nozzles –...

  • Page 5: About These Instructions

    General information This operating manual contains all important information which you require for the working with the OptiSelect Pro GM04. 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

    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 Pro GM04...

  • 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 Pro GM04...

  • 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 Pro GM04...

  • Page 10: Reasonably Foreseeable Misuse

    Rev. 01 08/19 Reasonably foreseeable misuse – Use with insufficient compressed air quality – Input pressure too low Technical Data Electrical data OptiSelect Pro GM04 Nominal input voltage eff. 10 V Frequency 18 kHz (average) Nominal output voltage 110 kV negative
 (optional...

  • Page 11: Structure

    Spray nozzle system 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 Product description  11 OptiSelect Pro GM04...

  • Page 12: Operating Elements

    Flat jet nozzle NF40, complete (incl. electrode holder) – Flat jet nozzle NF20, complete (incl. electrode holder) – Cable tie with Velcro closure – Gun cleaning brush – Spare parts kit – Operating manual 12  Product description OptiSelect Pro GM04...

  • 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 Pro GM04...

  • 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 Pro GM04...

  • 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 Pro GM04...

  • Page 16: Flat Jet Nozzle With Vented Central Electrode

    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 Pro GM04...

  • Page 17: Typical Characteristics - Properties Of The Functions

    Quick and simple connection and disconnection from powder hose and application cup – Protective function through to grounded clip ring Connection for SuperCorona Ring – Quick and simple connection to and disconnection from the SuperCorona ring Product description  17 OptiSelect Pro GM04...
  • Page 18 Rev. 01 08/19 18  Product description OptiSelect Pro GM04...

  • 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 Pro GM04...
  • Page 20 Rev. 01 08/19 fig. 8 Maintenance unit PowerClean™ module Injector (Option) Fluidizing air hose 20  Assembly / Connection OptiSelect Pro GM04...

  • Page 21: 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  21 OptiSelect Pro GM04...

  • Page 22: Initial Start-Up

    9 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")! 22  Start-up OptiSelect Pro GM04...

  • 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 Pro GM04...

  • Page 24: Setting The Electrode Rinsing Air

    Setting the electrode rinsing air Press the key. The second display level will be shown. Adjust the correct electrode rinsing air according to the applied nozzles (deflector plate, flat jet nozzle) 24  Operation OptiSelect Pro GM04...

  • Page 25: 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 Operation  25 OptiSelect Pro GM04...
  • 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 Pro GM04...
  • Page 27 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. Operation  27 OptiSelect Pro GM04...
  • Page 28 Rev. 01 08/19 28  Operation OptiSelect Pro GM04...

  • 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 Pro GM04...

  • 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 Pro GM04...

  • Page 31: Maintenance / Repairs

    – The parts to be replaced during maintenance work are available as spare parts. These parts can be found in the appropriate spare parts list! Maintenance / Repairs  31 OptiSelect Pro GM04...

  • Page 32: Gun Cleaning

    If the spray nozzle is just fitted loosely, there is danger of a flash- over of the gun high voltage, which can damage the gun! ► Always tighten the threaded sleeve well! 32  Maintenance / Repairs OptiSelect Pro GM04...

  • 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 08/19 Dismantling procedure 34  Maintenance / Repairs OptiSelect Pro GM04...
  • Page 35 Rev. 01 08/19 Assembling the powder gun The assembling is to be carried out in the reverse order to that shown above. Maintenance / Repairs  35 OptiSelect Pro GM04...
  • Page 36 Rev. 01 08/19 36  Maintenance / Repairs OptiSelect Pro GM04...

  • Page 37: 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  37 OptiSelect Pro GM04...
  • Page 38 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 38  Fault clearance OptiSelect Pro GM04...

  • Page 39: 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 40 Rev. 01 08/19 40  Disposal OptiSelect Pro GM04...

  • Page 41: 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  41 OptiSelect Pro GM04...

  • Page 42: Optiselect Pro Gm04 - Spare Parts List

    1016 973 gun cable 12 m, rinsing air hose 12 m, positive polarity (+) 1016 974 Manual powder gun shaft OptiSelect Pro GM04 (incl. cascade) with: Gun cable 6 m, negative polarity (–) 1018 700 Gun cable 12 m, negative polarity (–)
  • Page 43 Powder hose – Ø 10 mm (not shown) 1001 673*# Powder hose – Ø 11 mm (not shown) 105 139*# * Please indicate length # Wearing part fig. 10: OptiSelect Pro GM04 – spare parts Spare parts list  43 OptiSelect Pro GM04...

  • Page 44: 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 O-ring – Ø 27x2 mm 1009 525 # Wearing part fig. 11 44  Spare parts list OptiSelect Pro GM04...

  • Page 45: Supercorona

    Rev. 01 08/19 SuperCorona SuperCorona PC.. 1018 291# # Wearing part fig. 12 Spare parts list  45 OptiSelect Pro GM04...

  • Page 46: 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 46  Spare parts list OptiSelect Pro GM04...

  • Page 47: Round Jet Nozzles - Overview (Wearing Parts)

    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  47 OptiSelect Pro GM04...

  • Page 48: Gun Extensions

    ► The extensions (150 mm/300 mm) may be connected TO ONLY ONE ADDITONAL extension (150 mm/300 mm), if necessary. 48  Spare parts list OptiSelect Pro GM04...

  • Page 49: Spray Nozzles For Extensions - Overview (Wearing Parts)

    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  49 OptiSelect Pro GM04...

  • Page 50: Powder Hoses - Overview

    - Ø 12/18 mm 1001 674 high powder flow * Please indicate length Other accessories 150 ml 500 ml Application cup 1004 552 1002 069 Gloves, anti-static (1 pair) 800 254 50  Spare parts list OptiSelect Pro GM04...
  • Page 51 Safety symbols ..........5 Spare parts list ..........41 Start-up ............21 Storage ............29 Intended use ............9 Storage conditions ........... 29 Maintenance ............. 31 Technical Data ..........10 Maintenance during storage ......30 Index  51 OptiSelect Pro GM04...
  • Page 52 Rev. 01...

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