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Rev. 00 01/20

OptiSelect Pro GM04-E

Maintenance / Repairs



29

Maintenance / Repairs

Interval

Gun maintenance

The gun is designed to require only a minimum amount of maintenance.

1.

Clean the gun with dry cloth, see chapter "Maintenance"

2.

Check connection points to powder house.

3.

Replace the powder hoses, if necessary.

Reinigung

Cleaning

ATTENTION

Any unauthorized modifications and alterations to the product are
not permitted for safety r

easons 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!

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Содержание OptiSelect Pro GM04-E

Страница 1: ...Rev 00 1017 570 EN Operating instructions and Spare parts list Manual gun OptiSelect Pro GM04 E Translation of the original operating instructions ...

Страница 2: ...s 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 tr...

Страница 3: ...ical 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 propert...

Страница 4: ...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 ...

Страница 5: ...nual 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 WA...

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: ...gulations 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 t...

Страница 9: ...g 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 responsi...

Страница 10: ...0 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 ...

Страница 11: ...rall 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 ...

Страница 12: ...age 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 ...

Страница 13: ...3 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 ...

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: ...rode 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 ...

Страница 16: ...pray 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...

Страница 17: ...al 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 oper...

Страница 18: ...Rev 00 01 20 18 Product description OptiSelect Pro GM04 E ...

Страница 19: ...pressed 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 inj...

Страница 20: ...Rev 00 01 20 20 Assembly Connection OptiSelect Pro GM04 E fig 7 1 Gun 2 Injector 3 Fluidizing air hose 4 Maintenance unit ...

Страница 21: ...ons 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: ... see the troubleshooting guide as well as the gun control unit operating manual fig 8 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: ...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 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 to...

Страница 24: ...ir 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 ...

Страница 25: ... The rinsing mode enables blowing off powder accumulations in the powder hose Activating the rinsing function Manual equipment 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 suction hose must be disconnected prior to cleaning procedure on type B the suction unit must be lifted 1 Detach the...

Страница 26: ...l 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 4 STOP OR OR the cleaning mode is terminated automatically After completion of the PowerClean procedure the controller...

Страница 27: ...es 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 r...

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: ...r 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 a...

Страница 30: ...outside 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 conn...

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 01 20 32 Maintenance Repairs OptiSelect Pro GM04 E Dismantling procedure 1 2 3 ...

Страница 33: ...Rev 00 01 20 OptiSelect Pro GM04 E Maintenance Repairs 33 Assembling the powder gun The assembling is to be carried out in the reverse order to that shown above 1 ...

Страница 34: ...Rev 00 01 20 34 Maintenance Repairs OptiSelect Pro GM04 E ...

Страница 35: ...here 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 Conne...

Страница 36: ...only 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 ...

Страница 37: ... 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 01 20 38 Disposal OptiSelect Pro GM04 E ...

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: ...1 2 Cascade complete negative polarity incl pos 3 1016 911 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 connection 1017 684 10 Gun cable 6 m complete 1016 952 Gun cable 12 m complete 1016 953 11 Rinsing air connection 1017 656 11 1 Rinsing air hose 100 854 12 Powd...

Страница 41: ...Rev 00 01 20 OptiSelect Pro GM04 E Spare parts list 41 Powder hose Ø 16 11 mm not shown 103 128 Please indicate length Wearing part fig 9 OptiSelect Pro GM04 E spare parts ...

Страница 42: ...lete 1002 249 12 Muzzle NS11 E complete 1009 439 13 Threaded sleeve PU04 E NS complete 405 736 14 Deflector Ø 15 mm 400 262 14 1 Deflector Ø 24 mm 400 181 14 2 Deflector Ø 28 mm 400 254 14 3 Deflector Ø 32 mm 400 238 14 4 Deflector Ø 50 mm 400 246 20 Extension PE08 E 150 complete 150 mm 1010 501 20 1 Extension PE08 E 300 complete 300 mm 1010 502 Wearing part ATTENTION Connecting more than two exte...

Страница 43: ...Rev 00 01 20 OptiSelect Pro GM04 E Spare parts list 43 Nozzle combinations fig 10 Nozzle combinations ...

Страница 44: ...Rev 00 01 20 44 Spare parts list OptiSelect Pro GM04 E Other accessories Gloves anti static 1 pair 800 254 ...

Страница 45: ...lt 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 PowerBoost function activation 17 Presentation of the contents 6 Product description 9 Product specific security regulations 8 R Remote control 17 Repairs 29 S Safety 7 Safety symbols 5 Spare parts list 39 Sta...

Страница 46: ...Rev 00 ...

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