Gema OptiSelect Pro GM04 Guide

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

Rev. 01 08/19
Documentation OptiSelect Pro GM04
© Copyright 2018 Gema Switzerland GmbH
All rights reserved.
This publication is protected by copyright. Unauthorized copying is
prohibited by law. No part of this publication may be reproduced,
photocopied, translated, stored on a retrieval system or transmitted in any
form or by any means for any purpose, neither as a whole nor partially,
without the express written consent of Gema Switzerland GmbH.
Gema, EquiFlow, MagicCompact, MagicCylinder, OptiCenter, OptiFlex,
OptiGun, OptiSelect and OptiStar are registered trademarks of Gema
Switzerland GmbH.
ClassicLine, ClassicStandard, ClassicOpen, DVC (Digital Valve Control),
GemaConnect, MagicControl, MagicPlus, MonoCyclone, MRS,
MultiColor, MultiStar, OptiAir, OptiControl, OptiColor, OptiFeed, OptiFlow,
OptiHopper, OptiMove, OptiSieve, OptiSpeeder, OptiSpray, PCC (Precise
Charge Control), RobotGun, SIT (Smart Inline Technology) und
SuperCorona are trademarks 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 trademarks of the copyright holders.
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.
For the latest information about Gema products, visit
www.gemapowdercoating.com.
For patent information, see www.gemapowdercoating.com/patents or
www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone:[phone]
Fax.: [phone]
E-mail: [email protected]

Rev. 01 08/19
OptiSelect Pro GM04 Table of contents
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3
Table of contents
About these instructions 5
General information ................................................................................................5
Keeping the Manual................................................................................................5
Safety symbols (pictograms)...................................................................................5
Structure of Safety Notes...........................................................................6
Presentation of the contents...................................................................................6
Figure references in the text......................................................................6
Safety 7
General information ................................................................................................7
Basic safety instructions .........................................................................................7
Product specific security regulations ......................................................................8
Product description 9
Intended use ...........................................................................................................9
Reasonably foreseeable misuse..............................................................10
Technical Data......................................................................................................10
Electrical data ..........................................................................................10
Dimensions ..............................................................................................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
Typical characteristics –properties of the functions.............................................17
Remote control.........................................................................................17
Powder hose quick release connection...................................................17
Connection for SuperCorona Ring...........................................................17
Assembly / Connection 19
Connecting the gun...............................................................................................19
Start-up 21
Preparation for start-up.........................................................................................21
Basic conditions.......................................................................................21
Initial start-up.........................................................................................................22

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Table of contents OptiSelect Pro GM04
Operation 23
Operation.............................................................................................................. 23
Setting powder output and powder cloud................................................ 23
Setting the electrode rinsing air............................................................... 24
Rinsing mode........................................................................................................ 25
Activating the rinsing function.................................................................. 25
Decommissioning / Storage 29
Decommissioning................................................................................................. 29
If in disuse for several days..................................................................... 29
Storage conditions................................................................................................ 29
Hazard notes........................................................................................... 29
Type of storage........................................................................................ 29
Storage duration...................................................................................... 29
Space requirements ................................................................................ 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 ........................................................................................... 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
PowerClean™ module (Option)............................................................................ 44
SuperCorona ........................................................................................................ 45
Accessories .......................................................................................................... 46
Flat jet nozzles –overview (wearing parts)............................................. 46
Round jet nozzles –overview (wearing parts)......................................... 47
Gun extensions........................................................................................ 48
Spray nozzles for extensions –overview (wearing parts)....................... 49
Powder hoses –overview........................................................................ 50
Other accessories.................................................................................... 50

Rev. 01 08/19
OptiSelect Pro GM04 About these instructions

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.
Information about the functional mode of the individual system
components should be referenced in the respective enclosed documents.
Keeping the Manual
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.
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
ATTENTION
Indicates a potentially harmful situation. If not avoided, the equipment or
something in its surrounding may be damaged.

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About these instructions OptiSelect Pro GM04
ENVIRONMENT
Indicates a potentially harmful situation which, if not avoided, may have
harmful consequences for the environment.
MANDATORY NOTE
Information which must be observed.
NOTICE
Useful information, tips, etc.
Structure 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:
"The high voltage (H) created in the gun cascade is guided through the
center electrode."

Rev. 01 08/19
OptiSelect Pro GM04 Safety

7
Safety
General information
This chapter provides the user and third parties who operate this product
with all essential safety regulations, the adherence to which is imperative.
These safety regulations must be read and understood in their entirety
before the product is put into operation.
The standards and guidelines applied during the development,
manufacture and configuration are described in the EC declaration of
conformity and in the manufacturer’s declaration.
WARNING
Working without instructions
Working without instructions or with individual pages from the
instructions may result in damage to property and personal injury
if relevant safety information is not observed.
►Before working with the device, organize the required documents
and read the section "Safety 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 manufacturer shall
not be liable for damage resulting from such use; the user bears sole
responsibility for such actions. If this product is to be used for other
purposes or other substances outside of our guidelines then Gema
Switzerland GmbH should be consulted.
–Start-up (i.e. the execution of intended operational tasks) is
forbidden until it has been established that this product has been set
up and wired according to the guidelines for machinery. The
standard "Machine safety" must also be observed.
–Unauthorized modifications to the product exempt the manufacturer
from any liability from resulting damage.

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
Safety OptiSelect Pro GM04
–The relevant accident prevention regulations, as well as other
generally recognized safety regulations, occupational health and
structural regulations are to be observed.
–Furthermore, the country-specific safety regulations also must be
observed.
Product specific security regulations
–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
local regulations before start-up.
For further security information, see the more detailed Gema
safety regulations!

Rev. 01 08/19
OptiSelect Pro GM04 Product description

9
Product description
Intended use
This gun is used for electrostatic coating of objects connectable to ground
with organic powders in conjunction with the control units and
accessories, as specified in the corresponding Type Examination
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 incorrect use and the risks associated with such
actions are assumed by the user alone!

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
Product description OptiSelect Pro GM04
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
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 powder
yes
Metallic powder
yes
Enamel powder
no