Gema OptiSelect Pro GM04-E Guide

Rev. 00 1017 570 EN
Operating instructions and Spare parts list
Manual gun
OptiSelect Pro GM04-E
Translation of the original operating instructions

Rev. 00 01/20
Documentation OptiSelect Pro GM04-E
© Copyright 2020 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. 00 01/20
OptiSelect Pro GM04-E 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
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 electrodes ...............16
Typical properties –characteristics 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-E
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 27
Decommissioning................................................................................................. 27
If in disuse for several days..................................................................... 27
Storage conditions................................................................................................ 27
Hazard notes........................................................................................... 27
Type of storage........................................................................................ 27
Storage duration...................................................................................... 27
Space requirements ................................................................................ 27
Physical requirements............................................................................. 28
Maintenance during storage................................................................................. 28
Maintenance schedule............................................................................. 28
Maintenance works.................................................................................. 28
Maintenance / Repairs 29
Interval.................................................................................................................. 29
Gun maintenance.................................................................................... 29
Cleaning................................................................................................................ 29
Gun cleaning ........................................................................................... 30
Cleaning the spray nozzle....................................................................... 30
Replacing parts........................................................................................ 31
Dismantling the gun................................................................................. 31
Fault clearance 35
Disposal 37
Introduction........................................................................................................... 37
Requirements on personnel carrying out the work.................................. 37
Disposal regulations................................................................................ 37
Materials.................................................................................................. 37
Spare parts list 39
Ordering spare parts............................................................................................. 39
OptiSelect Pro GM04-E –spare parts list ............................................................ 40
Nozzle combinations ............................................................................................ 42
Nozzle combinations ............................................................................................ 43
Other accessories.................................................................................... 44

Rev. 00 01/20
OptiSelect Pro GM04-E 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-E. 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-E
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."

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OptiSelect Pro GM04-E 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-E
–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. 00 01/20
OptiSelect Pro GM04-E Product description

9
Product description
Intended use
This gun is used for electrostatic coating of objects connectable to ground
with inorganic, non-flammable enamel 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 the intended 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 not considered as intended use. 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-E
Reasonably foreseeable misuse
–Coating of non grounded objects
–Use of metallic or organic powder
–Incorrectly configured values for powder conveyance
–Incorrectly configured values for electrode rinsing air
–Use of moist powder
Technical Data
Electrical data
OptiSelect Pro GM04-E
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 (incl. accessories)
Basic model for organic powder
OptiSelect Pro GM04
0102 II 2 D
PTB 11 ATEX 5006-1
Enamel version
OptiSelect Pro GM04-E
Dimensions
OptiSelect Pro GM04-E
Weight
700 g
Processible powders
OptiSelect Pro GM04-E
Enamel powder
yes
Plastic powder
no
Metallic powder
no

Rev. 00 01/20
OptiSelect Pro GM04-E Product description

11
Structure
Overall 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

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
Product description OptiSelect Pro GM04-E
Operating elements
LED and remote control buttons
fig.
3
Designation
Function
L1
Display High voltage (intensity)
T1
Key Increase value
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
–Rinsing air hose (6 m)
–Flat jet nozzle NF28-E, complete (incl. electrode holder)
–Cable tie with Velcro closure
–Gun cleaning brush
–Spare parts kit
–Operating manual

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OptiSelect Pro GM04-E Product description

13
Available accessories**
–SuperCorona ring
–Flat jet nozzles
–Round jet nozzles
–Gun extension 150 and 300 mm
–Gun cable extensions
–Various adapters for connection to earlier generations of control
units
–Gloves, anti-static
**for more information, see spare parts list

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
Product description OptiSelect Pro GM04-E
SuperCorona ring
Field of application
The SuperCorona is an optional extension for the gun, allowing for a
better surface quality when coating with the powder coating equipment.
When coating wheel rims, drawers, radiators, lamps etc. the surface
quality is exceptional, also in places with higher coating layer
requirements. By coating with several powder types, an "orange peel"
finish can be completely avoided. By coating with structure powder, the
"picture 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 SuperCorona (approx. 60 g). The gun remains repair-friendly and
easy to maintain even after reconfiguration.
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.

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OptiSelect Pro GM04-E Product description

15
Principle of operation
High voltage generation
The control unit supplies a high-frequency low voltage signal of approx.
10 V eff. This voltage is fed through the gun cable (1) to the high voltage
cascade (2) in the gun shaft.
In the high voltage cascade (2), the low voltage is high-transformed in a
first step (c). This primary high voltage is subsequently rectified and
multiplied in the high voltage cascade in a second step (d), until the
required high voltage is obtained at the end (approx. 110 kV). The high
voltage is now fed to the electrode (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 voltage, the powder transport and the rinsing air.
fig.
4
Powder flow and electrode rinsing air
The electrode rinsing air is used by vented spray nozzles and is
connected with its designated connection on the rear side of the gun
control unit (see the operating manual of the gun control unit). The
functions of the spray nozzles are described in the corresponding section
of this manual.

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
Product description OptiSelect Pro GM04-E
Flat jet nozzle with vented central electrode
The vented flat jet nozzle serves for the spraying and the charging of the
powder. The powder is charged by the central electrode (E). The high
voltage (H) created in the gun cascade is guided through the center
electrode.
fig.
5
In order to prevent powder from sintering on the electrode, compressed
air is used during the spray 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 electrodes
The vented deflector is used, to give the powder stream emerging from
the gun, a cloud formation. The powder is charged by radial arranged
electrodes (E). The high voltage (H) created in the gun cascade is guided
through the electrodes.
fig.
6
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.

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OptiSelect Pro GM04-E Product description
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17
Typical properties –characteristics of the functions
Remote control
Three possibilities are available:
1 Change the powder output + Activate/stop rinsing process (factory
setting)
2 Program change + Activate/stop rinsing process
3 Change the powder output + Activate/stop the PowerBoost function
The respective option is set in the OptiStar control unit in
accordance with system parameter P12.
–See therefore the corresponding operating manual.
–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 operating manual)
Powder hose quick release connection
–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

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Product description OptiSelect Pro GM04-E

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OptiSelect Pro GM04-E Assembly / Connection
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19
Assembly / Connection
Connecting the gun
The gun is delivered ready-to-use by the manufacturer. Just a few cables
and hoses must be connected.
The compressed 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 injector

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Assembly / Connection OptiSelect Pro GM04-E
fig.
7
1 Gun
2 Injector
3 Fluidizing air hose
4 Maintenance unit