Gema OptiSelect Pro GM04, Operating Instructions And Spare Parts List

Page 1: ...Rev 01 1011 543 EN Operating instructions and Spare parts list Manual gun OptiSelect Pro GM04 Translation of the original operating instructions ...

Page 2: ... of 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 tra...

Page 3: ...ions 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...

Page 4: ...le 30 Maintenance works 30 Maintenance Repairs 31 Interval 31 Gun maintenance 31 Cleaning 31 Gun cleaning 32 Cleaning the spray nozzle 32 Replacing parts 33 Dismantling the gun 33 Fault clearance 37 Disposal 39 Introduction 39 Requirements on personnel carrying out the work 39 Disposal regulations 39 Materials 39 Spare parts list 41 Ordering spare parts 41 OptiSelect Pro GM04 spare parts list 42 P...

Page 5: ...al Please 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 WARN...

Page 6: ...of 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 Th...

Page 7: ...afety 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 T...

Page 8: ...ulations 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 th...

Page 9: ...mination 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 inc...

Page 10: ...ncy 18 kHz average Nominal output voltage 110 kV Polarity negative optional positive Max output current 110 µA High voltage display with LED Ignition protection Ex 2 mJ T6 Temperature range 5 C 40 C 41 F 104 F Max surface temperature 85 C 185 F Protection type IP64 Approvals 0102 II 2 D PTB 19 ATEX 5001 Dimensions OptiSelect Pro GM04 Weight 550 g Processible powders OptiSelect Pro GM04 Plastic pow...

Page 11: ...all view fig 2 1 Spray nozzle system 2 Threaded sleeve 3 Shaft 4 Rear part with hook 5 Remote control 6 SuperCorona connection 7 Gun handle 8 Gun cable 9 Powder hose connection 10 Powder hose quick release connection grounded 11 Electrode rinsing air connection 12 Trigger ...

Page 12: ...e T2 Key Decrease value T3 Key P Function according to system parameter in the OptiStar control unit Scope of delivery manual gun with gun cable 6 m negative polarity Powder hose 6 m Rinsing air hose 6 m 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 ...

Page 13: ...its 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 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 powders In moist or tropi...

Page 14: ...cture frame 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 Due to its modular structure the gun can be fast and easily extended with the light S...

Page 15: ...ode 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 l...

Page 16: ...process The electrode 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 th...

Page 17: ...l Adapt powder output The powder output is correspondingly increased or reduced Program change It is switching between programs P01 P20 Activating Deactivating the rinse mode the entire powder line from the suction area to the gun is rinsed direct temporary activation of the PowerBoost function Press again to return to the previous setting See therefore the corresponding OptiStar CG21 CG23 P opera...

Page 18: ...Rev 01 08 19 18 Product description OptiSelect Pro GM04 ...

Page 19: ...ressed 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 inje...

Page 20: ...Rev 01 08 19 20 Assembly Connection OptiSelect Pro GM04 fig 8 1 Gun 2 Injector 3 Fluidizing air hose 4 Maintenance unit 5 PowerClean module Option ...

Page 21: ...ns 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: ...see the troubleshooting guide as well as the gun control unit operating manual fig 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 ...

Page 23: ...loud 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 tot...

Page 24: ...r 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 the key The second display level will be shown 2 A...

Page 25: ... 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 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 ...

Page 26: ...insing 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 ...

Page 27: ...llel cleaning of other components such as the fluid intake unit powder container etc The rinsing 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 3 STOP OR OR the cleaning mode is terminated automatically After completion of the PowerClean procedure the control...

Page 28: ...Rev 01 08 19 28 Operation OptiSelect Pro GM04 ...

Page 29: ...s 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 re...

Page 30: ...ements 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: ... hoses if necessary Reinigung Cleaning ATTENTION Any unauthorized modifications and alterations to the product are not permitted for 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 ar...

Page 32: ...utside of the gun and wipe clean etc Weekly 2 Remove powder hose 3 Remove the spray nozzle from the gun and clean it with compressed air 4 Blow through the gun with compressed air beginning from the connection in flow direction 5 Clean the integrated gun tube with the brush supplied if necessary 6 Blow through the gun with compressed air again 7 Clean the powder hose 8 Reassemble the gun and conne...

Page 33: ...n 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 Dismantling the gun General information The gun should only be dismantl...

Page 34: ...Rev 01 08 19 34 Maintenance Repairs OptiSelect Pro GM04 Dismantling procedure 1 2 3 ...

Page 35: ...Rev 01 08 19 OptiSelect Pro GM04 Maintenance Repairs 35 Assembling the powder gun The assembling is to be carried out in the reverse order to that shown above 1 ...

Page 36: ...Rev 01 08 19 36 Maintenance Repairs OptiSelect Pro GM04 ...

Page 37: ...ere 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 Connec...

Page 38: ...nly 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 39: ...by 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 a...

Page 40: ...Rev 01 08 19 40 Disposal OptiSelect Pro GM04 ...

Page 41: ...18 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 usi...

Page 42: ...able 6 m positive polarity 1018 702 Gun cable 12 m positive polarity 1018 703 1 Gun body complete 1017 680 2 Cascade complete negative polarity incl pos 3 1016 911 Cascade complete positive polarity incl pos 3 1016 912 3 Buffer 1017 704 4 Print holder complete 1017 690 5 Rear part 1017 683 6 Trigger complete 1017 686 7 Trigger cover 1017 688 8 Countersunk head screw M4x6 mm 1017 698 9 SuperCorona ...

Page 43: ...s set not shown consisting of 1008 302 Multi spray adapter 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 10 OptiSelect Pro GM04 spare parts ...

Page 44: ...lean module 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 O ring Ø 27x2 mm 1009 525 Wearing part fig 11 ...

Page 45: ...Rev 01 08 19 OptiSelect Pro GM04 Spare parts list 45 SuperCorona 1 SuperCorona PC 1018 291 Wearing part fig 12 ...

Page 46: ...010 090 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 Profiles big flat parts standard nozzle NF40 1018 165 NF40 1018 166 1008 326 Large surfaces NF24 1008 147 NF24 1008 142 not suitable for angled nozzles ...

Page 47: ...04 Spare parts list 47 Round jet nozzles 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 ...

Page 48: ...7 746 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 49: ... 1007 718 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 ...

Page 50: ...er Parts No Material Type Fast 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 Gloves anti static 1 pair 800 254 ...

Page 51: ... clearance 37 Figure references in the text 6 I Intended use 9 M Maintenance 31 Maintenance during storage 30 N Nozzles Flat jet nozzle 16 O Operation 23 P Pictograms 5 PowerBoost function activation 17 PowerClean module 13 Presentation of the contents 6 Product description 9 Product specific security regulations 8 R Remote control 17 Repairs 31 S Safety 7 Safety symbols 5 Spare parts list 41 Star...

Page 52: ...Rev 01 ...