Gema OptiSelect GM03, Operating Instructions And Spare Parts List

Page 1: ...Rev 01 1011 454 EN Operating instructions and Spare parts list Manual gun OptiSelect GM03 Translation of the original operating instructions ...

Page 2: ...f Gema Switzerland 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 trade...

Page 3: ...ns 10 Processible powders 10 Structure 11 Overall view 11 Operating elements 12 Scope of delivery 12 Available accessories 13 PowerClean module Option 13 SuperCorona ring 14 Principle of operation 15 High voltage generation 15 Circuit 15 Powder flow and electrode rinsing air 15 Flat jet nozzle with vented central electrode 16 Round jet nozzle with vented deflector and vented central electrode 16 T...

Page 4: ...rements 29 Physical requirements 30 Maintenance during storage 30 Maintenance schedule 30 Maintenance works 30 Maintenance Repairs 31 Interval 31 Gun maintenance 31 Cleaning 31 Gun cleaning 31 Cleaning the spray nozzle 32 Replacing parts 33 Fault clearance 35 Disposal 37 Introduction 37 Requirements on personnel carrying out the work 37 Disposal regulations 37 Materials 37 Spare parts list 39 Orde...

Page 5: ...lease keep this Manual ready for later use or if there should be any queries Safety symbols pictograms The following warnings with their meanings can be found in the Gema instructions The general safety precautions must also be followed as well as the regulations in the relevant instructions DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING ...

Page 6: ... Safety Notes Every note consists of 4 elements Signal word Nature and source of the danger Possible consequences of the danger Prevention of the danger SIGNAL WORD Nature and source of the hazard Possible consequences of the danger Prevention of the danger Presentation of the contents Figure references in the text Figure references are used as cross references in the descriptive text Example The ...

Page 7: ...ety regulations Work should only be carried out in accordance with the instructions of the relevant documents Always work with the complete original document Basic safety instructions This product is built to the latest specification and conforms to the recognized technical safety regulations and is designed for the normal application of powder coating Any other use is considered non compliant The...

Page 8: ...ations This product 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 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 ...

Page 9: ...nation Certificate fig 1 Observance of the operating service and maintenance instructions specified by the manufacturer is also part of conformity of use This product should only be used maintained and started up by trained personnel who are informed about and are familiar with the possible hazards involved Any other use is considered non compliant The manufacturer is not responsible for any incor...

Page 10: ...ncy 18 kHz average Nominal output voltage 100 kV Polarity negative optional positive Max output current 100 µA High voltage display with LED Ignition protection Ex 2 mJ T6 Temperature range 0 C 40 C 32 F 104 F Max surface temperature 85 C 185 F Protection type IP64 Approvals 0102 II 2D PTB 11 ATEX 5006 Dimensions OptiSelect GM03 Weight 520 g Processible powders OptiSelect GM03 Plastic powder yes M...

Page 11: ...ew fig 2 1 Spray nozzle system 2 Threaded sleeve 3 Shaft 4 Cover with remote control and hooks 5 Remote control 6 SuperCorona connection 7 Gun handle 8 Gun cable 9 Powder hose connection 10 Powder hose quick release connection 11 Electrode rinsing air connection 12 Trigger ...

Page 12: ...intensity T1 Powder output key T2 Powder output key T3 Activate stop rinsing process key Scope of delivery Manual gun with gun cable 6 m negative polarity Powder hose 6 m ID 10 mm 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 ...

Page 13: ...of control units Gloves anti static for more information see spare parts list PowerClean module Option Field of application The PowerClean module can be used in combination with the OptiStar CG09 CG13 control unit The PowerClean module provides increased stability in application processes It prevents the bridging phenomena that can lead to short circuiting when handling powders such as metallic po...

Page 14: ...rame effect is hardly visible The performance of the gun with SuperCorona is convincing due to its very good charging and very high deposition rate as well as an improved penetration into Faraday cages The distance between nozzle and workpiece can be reduced to 100 mm without influencing the surface finish fig 5 Due to its modular structure the gun can be fast and easily extended with the light Su...

Page 15: ...e E within the spray nozzle Circuit In addition to the modulated low voltage needed for high voltage generation there are signal lines fed trough the gun cable The control signals are used for monitoring gun trigger status and gun remote control functions The gun is released by a touch free switch 3 which is operated by a magnet 4 in the trigger 5 The gun control unit switches on the modulated low...

Page 16: ...ay process The rinsing air S adjustment on the gun control unit is described in the corresponding operating manual Round jet nozzle with vented deflector and vented central electrode The vented deflector is used to give the powder stream emerging from the gun a cloud formation The powder is charged by the central electrode E The high voltage H created in the gun cascade is guided through the cente...

Page 17: ...rams P01 P20 See chapter Activate deactivate the program change function via remote control on page 27 Activate stop PowerClean process injector powder hose and gun are rinsed only if the optional PowerClean module is present and attached Powder hose quick release connection Quick and simple connection and disconnection from powder hose and application cup Connection for SuperCorona Ring Quick and...

Page 18: ...Rev 01 08 16 18 Product description OptiSelect GM03 ...

Page 19: ...ssed air must be free of oil and water The gun is connected as follows 1 Connect electrode rinsing air hose and powder hose to gun 2 Lay out gun cable electrode rinsing air hose and powder hose and bind using Velcro strips included 3 Connect the gun cable plug to the socket 2 3 on the rear side of the control unit 4 Connect electrode rinsing air hose to coupling 1 4 5 Connect powder hose to inject...

Page 20: ...Rev 01 08 16 20 Assembly Connection OptiSelect GM03 fig 9 1 Gun 2 Injector 3 Fluidizing air hose 4 Maintenance unit 5 PowerClean module Option ...

Page 21: ... 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 ...

Page 22: ...s see the troubleshooting guide as well as the gun control unit operating manual 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 ...

Page 23: ...ud The powder output depends on the selected powder output in and the powder cloud on the selected total air volume As a factory default value a powder rate of 50 and a total air volume of 4 Nm h are recommended If values are entered that the gun control unit cannot implement then the operator is informed of this by a blinking in the relevant display and a temporary error message Setting the total...

Page 24: ...0 is recommended for initial operation The total air volume is thereby kept constant automatically by the control unit To achieve maximum efficiency we recommend avoided an overly high powder volume where possible 2 Check fluidization of the powder in the powder container 3 Point the gun into the booth switch the gun on and visually check the powder output Setting the electrode rinsing air 1 Press...

Page 25: ... mode The rinsing mode enables blowing off powder accumulations in the powder hose Activating the rinsing function Manual equipment without optional PowerClean module system parameter P01 0 The rinsing mode can only be activated from standby mode main menu display no powder conveying On OptiFlex 2 F Manual coating equipment the injector must be disconnected prior to cleaning procedure on OptiFlex ...

Page 26: ...sing mode is exited if the automatic rinsing sequence has finished Manual manual The operator controls the number and length of the PowerClean impulse by pressing the gun trigger a second time 4 STOP or or the cleaning mode is terminated automatically After completion of the PowerClean procedure the controller switches back to coating mode Manual equipment with optional PowerClean module system pa...

Page 27: ...se by pressing the gun trigger a second time 3 STOP or or the cleaning mode is terminated automatically After completion of the PowerClean procedure the controller switches back to coating mode Activate deactivate the program change function via remote control The remote control function has been set in the factory to change the powder output If the operator prefers the possibility to switch betwe...

Page 28: ...Rev 01 08 16 28 Operation OptiSelect GM03 ...

Page 29: ...see therefore the corresponding user manuals 3 Turn off the compressed air main supply Storage conditions Hazard notes There is no danger to personnel or the environment if the unit is stored properly Type of storage For safety reasons the product should only be stored in a horizontal position Storage duration If the physical conditions are maintained the unit can be stored indefinitely Space requ...

Page 30: ...ents 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 ...

Page 31: ... safety reasons and exclude the manufacturer s liability for any resulting damage Regular and conscientious cleaning and maintenance increase the service life of the product and ensure consistent high coating quality The parts to be replaced during maintenance work are available as spare parts These parts can be found in the appropriate spare parts list Gun cleaning ATTENTION Impermissible solvent...

Page 32: ...irection 6 Clean the integrated gun tube with the brush supplied if necessary 7 Blow through the gun with compressed air again 8 Clean the powder hose 9 Reassemble the gun and connect it Cleaning the spray nozzle Daily or after every shift 1 Clean the inside and outside of the spray nozzle with compressed air Never immerse the parts in solvents 2 Check the seating of the spray nozzles ATTENTION Th...

Page 33: ...les with deflectors if the wedge of the electrode holder is worn down then the electrode holder is to be replaced 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 Contact your Gema representative ...

Page 34: ...Rev 01 08 16 34 Maintenance Repairs OptiSelect GM03 ...

Page 35: ...e to object although the gun is triggered and sprays powder High voltage and current deactivated Check the high voltage and current setting High voltage cascade defective Contact local Gema representative The objects are not properly grounded Check the grounding The gun does not spray powder although the control unit is switched on and the gun trigger is pressed Compressed air not present Connect ...

Page 36: ...y poor spray profile Total air incorrectly configured Increase the powder quantity and or total air volume on the control unit Bend or damage to air lines to injector Check air lines to injector Insert sleeve in the injector worn or not inserted Replace or insert it Fluidization not running see above ...

Page 37: ... Gema the instructions in the respective manufacturer s documentation must be observed Disposal regulations The product must be disassembled and disposed of properly at the end of its service life When disposing of the product the applicable local and regional laws directives and environmental regulations must be complied with Materials The materials must be sorted according to material groups and...

Page 38: ...Rev 01 08 16 38 Disposal OptiSelect GM03 ...

Page 39: ... 15 mm When ordering cable or hose material the required length must also be given The spare part numbers of this 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 ATTENTION Use of non original Gema spare parts When using...

Page 40: ... cable 2 m positive polarity 1007 974 Gun cable 6 m positive polarity 1007 975 Gun cable 12 m positive polarity 1007 968 1 Gun body 1007 220 2 Cascade complete negative polarity 1007 231 Cascade complete positive polarity 1007 232 3 Print holder complete 1007 216 4 End plate with hook 1007 217 5 Grip complete incl pos 5 1 and 5 2 1007 961 5 1 Grub screw M3x8 mm 1008 157 5 2 Grip sealing 1007 633 6...

Page 41: ...2 mm 389 765 Parts set not shown consisting of 1008 302 Flat jet nozzle NF21 1007 935 MultiSpray Adapter NF08 1003 634 Cable clamp 303 070 Hose connector complete for hose interior Ø 9 10 mm 1002 030 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 ...

Page 42: ... Option PowerClean module complete 1009 528 1 Elastomer valve 1000 089 2 O ring Ø 16x2 mm anti static 1007 794 3 Fluidizing tube bearing 1007 356 4 Fluidizing tube 1007 355 5 Retaining bracket 1009 524 6 Gasket 1010 101 7 O ring Ø 27x2 mm 1009 525 Wearing part fig 12 ...

Page 43: ...Rev 01 08 16 OptiSelect GM03 Spare parts list 43 SuperCorona 1 SuperCorona PC05 1008 165 Wearing part Fig 13 ...

Page 44: ...ofiles flat parts standard nozzle NF20 1010 090 1007 683 NF20 1010160 1007 229 Profiles flat parts NF27 1010 752 NF27 1010 754 Complex profiles and depressions NF21 1007 935 NF21 1007 932 Complex parts deep recess target spraying NF22 1008 145 NF22 1008 140 Large surfaces NF24 1008 147 NF24 1008 142 1008 326 not suitable for angled nozzles ...

Page 45: ...arts list 45 Round jet nozzle Overview wearing parts Application A B A B Threaded sleeve Deflectors Suitable for large surfaces NS04 1008 151 1008 152 NS04 1008 150 1007 229 Ø 16 mm 331 341 Ø 24 mm 331 333 Ø 32 mm 331 325 Ø 50 mm 345 822 ...

Page 46: ...746 1007 747 with Round jet nozzle NS09 1007 748 1007 749 1 see NF27 NF20 NF21 NF24 NS04 2 see NF25 NF26 NS09 ATTENTION Connecting more than two 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 ...

Page 47: ...1007 719 Application A B A B Threaded sleeve Deflecto rs Profiles flat parts NF25 1007 735 1007 684 NF25 1007 743 1007 740 Complex profiles and depressions NF26 1007 742 NF26 1007 744 Suitable for large surfaces NS09 1008 257 1008 258 NS09 1008 259 Ø 16 mm 331 341 Ø 24 mm 331 333 Ø 32 mm 331 325 Ø 50 mm 345 822 ...

Page 48: ...st color changes Ø 11 16 mm 105 139 POE 66 Fast color changes low powder flow Ø 10 15 mm 1001 673 POE 74 Fast color changes high powder flow Ø 12 18 mm 1001 674 POE 75 Please indicate length Other accessories Application cup 150 ml 500 ml 1004 552 1002 069 Gun extension cables L 6 m 1002 161 L 14 m 1002 162 Gloves anti static 1 pair 800 254 ...

Page 49: ... for several days 29 E Electrical data 10 F Fault clearance 35 Figure references in the text 6 I Intended use 9 M Maintenance 31 Maintenance during storage 30 O Operation 23 P Pictograms 5 Presentation of the contents 6 Product description 9 Product specific security regulations 8 R Repairs 31 S Safety 7 Safety symbols 5 Spare parts list 39 Start up 21 Storage 29 Storage conditions 29 T Technical ...

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