The Gema OptiSelect Pro GM04 is a manual powder coating gun designed for electrostatic coating of objects connectable to ground with organic powders. It operates in conjunction with control units and accessories as specified in its Type Examination Certificate.
Function Description
The gun functions by spraying and charging powder through a central electrode. High voltage, generated in the gun cascade, is guided through this central electrode to charge the powder. Compressed air is used during the spray process to prevent powder from sintering on the electrode. The gun offers remote control capabilities for adjusting powder output, activating/stopping the rinsing process, and changing programs. It also features a powder hose quick-release connection and a dedicated connection for the SuperCorona Ring.
Important Technical Specifications
Electrical Data:
- Nominal input voltage: 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: CE 0102 Ex II 2 D, PTB 18 ATEX 5001
Dimensions:
Processible Powders:
- Plastic powder: Yes
- Metallic powder: Yes
- Enamel powder: No
Air Consumption (approximate):
- Electrode rinsing air: ≈ 0.1 Nm³/h (for flat jet nozzle), ≈ 0.5 Nm³/h (for round jet nozzle)
Usage Features
The OptiSelect Pro GM04 is designed for ease of use and optimal coating results.
- Powder Output and Cloud Setting: The powder output depends on the selected powder output (in %), and the powder cloud on the selected total air volume. Factory default recommends 50% powder rate and 4 Nm³/h total air volume. Values that cannot be implemented by the control unit will cause a blinking display and temporary error message.
- Electrode Rinsing Air Adjustment: The electrode rinsing air can be adjusted on the gun control unit to prevent powder sintering and ensure proper operation with different nozzles (deflector plate, flat jet nozzle).
- Rinsing Mode: This mode allows for blowing off powder accumulations in the powder hose. It can be activated from standby mode (no powder conveying). For manual equipment without the optional PowerClean module, the injector must be disconnected (Type F), the suction unit lifted (Type B), or the powder container emptied (Type S) before cleaning.
- Remote Control: The gun features remote control buttons (L1, T1, T2, T3) for display of high voltage, increasing/decreasing values, and function according to system parameters in the OptiStar control unit.
- PowerBoost Function: This function allows for temporary activation of increased powder output.
- PowerClean™ Module (Option): This optional module enhances the rinsing process by enabling parallel cleaning of other components like the fluid intake unit and powder container. It improves stability in application processes, prevents bridging phenomena, and can handle powders such as metallic powders.
- SuperCorona Ring (Option): An optional extension that improves surface quality, especially for complex geometries like wheel rims and radiators. It helps avoid "orange peel" finish and reduces the "picture frame effect" with structure powder. It offers very good charging, high deposition rates, and improved penetration into Faraday cages. The gun remains repair-friendly and easy to maintain even with the SuperCorona attached.
- Nozzle Systems: The gun supports various spray nozzle systems, including flat jet nozzles with vented central electrodes and round jet nozzles with vented deflectors and central electrodes, to achieve different powder stream formations and coating characteristics.
- Gun Extensions: Extensions of 150 mm and 300 mm are available, with or without nozzles, to reach difficult areas. It is important not to connect more than two extensions to prevent damage from leverage force.
Maintenance Features
Regular and conscientious cleaning and maintenance are crucial for increasing the service life of the product and ensuring consistent high coating quality.
- Gun Maintenance Interval: The gun requires minimal maintenance. It should be cleaned with a dry cloth, connection points to the powder hose checked, and powder hoses replaced if necessary.
- Daily Cleaning: Blow off the outside of the gun and wipe it clean.
- Weekly Cleaning: Remove the spray nozzle and clean the inside with compressed air, removing any sinterings.
- Monthly Cleaning: Check the spray nozzle for wear. Flat jet nozzles should be replaced if the spray pattern is irregular, grooves appear in the nozzle slot, or the electrode holder wedge is worn. For nozzles with deflectors, the electrode holder should be replaced if its wedge is worn down.
- Gun Cleaning (General): Only cleaning agents with a flash point of at least 5 Kelvin above ambient temperature, or cleaning places with technical ventilation, are allowed. Impermissible solvents (e.g., ethylene chloride, acetone, methyl ethyl ketone, methylene chloride, premium gasoline, turpentine, tetrachloroethane, toluene, trichloroethylene, xylene) are prohibited.
- Spray Nozzle Cleaning: Clean the inside and outside of the spray nozzle with compressed air daily or after every shift. Never immerse parts in solvents. Ensure the threaded sleeve is always tightly fastened.
- Replacing Parts: Except for minor part replacements, the cascade and powder gun cable connection repairs should only be performed by an authorized Gema Service center.
- Dismantling: The gun should only be dismantled if necessary due to a defect or pollution, and only to the extent required to access the faulty part. Before dismantling, the control unit must be switched off and the gun plug disconnected to prevent discharge.
- Storage: For disuse of several days, separate the gun from power mains, clean guns, injectors, and powder hoses, and turn off the compressed air main supply. Store the product horizontally in a dry building at 5-50 °C, away from direct sunlight. Periodically perform a visual check during long-term storage.
- Spare Parts: Only original Gema spare parts should be used to ensure explosion protection and maintain warranty claims. Wearing parts are clearly marked in the spare parts list.
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