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Rev. 00

1017 572

Operating instructions and Spare parts list

Manual gun

OptiSelect Pro GM04-CF

Translation of the original operating instructions

Содержание OptiSelect Pro GM04-CF

Страница 1: ...Rev 00 1017 572 EN Operating instructions and Spare parts list Manual gun OptiSelect Pro GM04 CF Translation of the original operating instructions ...

Страница 2: ...ks 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 t...

Страница 3: ... data 10 Dimensions 10 Processible powders 10 Structure 11 Overall view 11 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 central electrode 16 Typical properties characteristics...

Страница 4: ...ance Repairs 29 Interval 29 Gun maintenance 29 Cleaning 29 Gun cleaning 30 Cleaning the spray nozzle 30 Replacing parts 31 Dismantling the gun 31 Plug gauge for checking wear of insert sleeves 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 Ordering spare parts 39 OptiSelect Pro GM04 CF sp...

Страница 5: ...anual 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 W...

Страница 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 T...

Страница 7: ... 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...

Страница 8: ...egulations 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 ...

Страница 9: ...amination 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 in...

Страница 10: ...e 110 kV Polarity negative optional positive Max output current 110 µA 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 CF Weight Funnel cup without cover 725 g Weight Funnel cup 300 ml with cover 130 g Weight Funnel cup 600 ml with cover 150 g Processib...

Страница 11: ... Structure Overall view fig 2 1 Spray nozzle system 2 Threaded sleeve 3 Shaft 4 Rear part with hook 5 Funnel cup 6 SuperCorona connection 7 Gun handle 8 Gun cable 9 Supplementary air connection 10 Injector 11 Rotary knob 12 Trigger 13 Conveying air connection ...

Страница 12: ...04 CF Scope of delivery manual gun with gun cable 6 m negative polarity Funnel cup 300 ml with cover Flat jet nozzle NF20 complete incl electrode holder Cable tie with Velcro closure Gun cleaning brush Multi spray adapter Spare parts kit Operating manual ...

Страница 13: ...lect Pro GM04 CF Product description 13 Available accessories SuperCorona ring Flat jet nozzles Round jet nozzles Gun extension 150 and 300 mm Funnel cup 600 ml Gloves anti static for more information see spare parts list ...

Страница 14: ...icture 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 ...

Страница 15: ...e 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 c...

Страница 16: ...lectrode rinsing air S can be adjusted on the gun control unit depending on the gun type see 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 ...

Страница 17: ...y material for durable use Reproducible coating parameters All pneumatic and electrostatic parameters of the application are precisely monitored and controlled via the gun control and the fully integrated injector module Fast color changes Thanks to tool free disassembly and full visibility of the powder transporting components a high quality color change can be performed very fast Connection for ...

Страница 18: ...Rev 00 03 20 18 Product description OptiSelect Pro GM04 CF ...

Страница 19: ...r side of the control unit 2 Connect the black quick release connection with integrated powder stop with the Quick release coupling of the supplementary air hose The supplementary air hose must already be connected to the output 1 3 on the rear side of the control unit 3 Connect the conveying air hose as well as the supplementary air hose to the gun 4 Lay out the gun cable conveying air hose and s...

Страница 20: ...Rev 00 03 20 20 Assembly Connection OptiSelect Pro GM04 CF fig 6 1 Gun control unit 2 Gun 3 Maintenance unit 4 Nut with screw cap 5 Closing coupling ...

Страница 21: ...ions 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 ...

Страница 22: ...s see the troubleshooting guide as well as the gun control unit operating manual fig 7 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 ...

Страница 23: ...attern make sure that the rotary knob is in the correct position Turn the rotary knob into the correct position fig 8 Bedienung Operation Setting powder output and powder cloud 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 2 5 Nm h are recommended If values ar...

Страница 24: ...tput 1 much powder little powder Adjust the powder output volume e g according to the desired coating thickness Factory default setting of 50 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 funn...

Страница 25: ...ir is automatically supplied to the electrode The prerequisite for this function is that the corresponding system parameter is already set correctly in the gun control unit ATTENTION A wrong parameterization leads to various malfunctions For more on this please also see the operating instructions for the corresponding gun control unit ...

Страница 26: ...Rev 00 03 20 26 Operation OptiSelect Pro GM04 CF ...

Страница 27: ...owder transport 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 indefin...

Страница 28: ...rements 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 ...

Страница 29: ...wear refer to chapter Plug gauge for checking wear 4 Replace the injector nozzle 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 consisten...

Страница 30: ... of the gun and wipe clean etc Weekly 2 Remove the application cup 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 application cup 8 Reassemble the gun and...

Страница 31: ...rn 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 dismant...

Страница 32: ...Rev 00 03 20 32 Maintenance Repairs OptiSelect Pro GM04 CF Dismantling procedure 1 2 3 ...

Страница 33: ...roduce a much lower powder output than new insert sleeves Wear on the insert sleeve occurs internally is hardly visible from the outside and the inlet diameter is not affected Wear and tear of the gun and components will depend on the intensity and amount of use of the gun and therefore should be checked regularly The condition of the insert sleeve can be checked with the insert sleeve still mount...

Страница 34: ...Rev 00 03 20 34 Maintenance Repairs OptiSelect Pro GM04 CF ert oder noch weniger sinken Replace worn insert sleeve see also Spare parts list 50 ...

Страница 35: ... representative Nozzle defective Replace 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 the equipment to the compressed air Insert sleeve in the injector module clogged or not inserted Clean or insert the corresponding part Nozzle in the injector modul...

Страница 36: ...y air not correctly connected or interchanged Connect the pneumatic hoses correctly refer to chapter Connecting the gun Air lines to the gun bent damaged or clogged Check air lines to gun Insert sleeve in the injector worn or not inserted Replace or insert it Powder doesn t flow through the cup Rotary knob is not in the correct position Powder with insufficient flow properties Turn the rotary knob...

Страница 37: ...d 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...

Страница 38: ...Rev 00 03 20 38 Disposal OptiSelect Pro GM04 CF ...

Страница 39: ... 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 us...

Страница 40: ...int holder complete 1019 655 5 Rear part 1019 675 6 Trigger complete 1017 686 7 Trigger cover 1017 688 8 Countersunk screw M4x6 mm 1017 698 9 SuperCorona connection 1017 684 10 Gun cable 6 m complete 1019 686 11 Rinsing air connection 1017 656 12 Connection tube complete incl pos 12 1 1001 488 12 1 O ring for pos 12 Ø 4x1 mm 234 877 13 Powder tube complete incl pos 13 1 13 2 13 3 1007 958 13 1 O r...

Страница 41: ...1019 693 Funnel cup 600 ml 1019 666 28 Cup cover Ø 80 mm complete 1019 724 Cup cover Ø 100 mm complete 1019 725 29 Screw M6x16 mm 1017 673 Cleaning brush Ø 12 mm not shown 389 765 Parts set not shown consisting of Insert sleeve 1019 673 Multi spray adapter 1003 634 Cable clamp 303 070 O ring Ø 10x2 mm 1019 668 O ring Ø 11x2 mm 1019 669 Please indicate length Wearing part fig 10 OptiSelect Pro GM04...

Страница 42: ...Rev 00 03 20 42 Spare parts list OptiSelect Pro GM04 CF SuperCorona 1 SuperCorona PC 1018 291 Wearing part fig 11 ...

Страница 43: ...ts 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 Profiles big flat parts NF40 1018 165 NF40 1018 166 1008 326 Large surfaces NF24 1008 147 NF24 1008 142 not suitable for angled nozzles ...

Страница 44: ... OptiSelect Pro GM04 CF 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 ...

Страница 45: ...07 746 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 necessar...

Страница 46: ...s 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 ...

Страница 47: ...Rev 00 03 20 OptiSelect Pro GM04 CF Spare parts list 47 Other accessories Gloves anti static 1 pair 800 254 ...

Страница 48: ......

Страница 49: ...trical data 10 F Fault clearance 35 Figure references in the text 6 I Intended use 9 M Maintenance 29 Maintenance during storage 28 N Nozzles Flat jet nozzle 16 Round jet nozzle 16 O Operation 23 P Pictograms 5 Presentation of the contents 6 Product description 9 Product specific security regulations 8 R Repairs 29 S Safety 7 Safety symbols 5 Shutdown 27 Spare parts list 39 Start up 21 Storage 27 ...

Страница 50: ...Rev 00 ...

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